May 2014

WHY EUROPE NEEDS TO ACT ON SHALE

EXTERNAL PIPELINE COATING IN RUSSIA
CONFERENCE: FIELD JOINT COATING 2014
THE ROLE OF POLITICS IN US PIPELINES
ISSN 2053-7204
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04 News
11 Europe needs to act on shale
Europe is lagging the world in its development of shale oil and gas. AMI Consulting
senior vice president Noru Tsalic looks at why shale is so important and counters
some of the arguments of opponents.
17 Functionalised approach to pipeline protection
Bredero Shaws SureBond 100 coating system uses functionalised PE to simplify
coating structure while offering improved mechanical and eld joint performance.
Cedric Oudinet explains more.
21 The politics of US pipelines
Key pipeline projects are facing intense and delaying scrutiny in the US, to the benet
of rail, barge and road transport operators. Nicholas Newman explains more and why
pipelines will, in the end, win out.
28 Denso wins Indian rehabilitation project
Denso secures a contract to supply 2.4m square metres of corrosion protection
products for Indian Oil Corporations pipeline rehabilitation programme.
31 External coatings for pipelines in Russia
Russias pipeline coating and rehabilitation market is large and demanding. Andrew
Chalov provides some insight into the main technologies in use in the country.
34 Conference preview: Exploring FJC innovations
AMIs rst Field Joint Coating conference takes place in Germany in September. We
take a look at the speaker line-up and preview some of the topics that will be covered.
36 Product update
contents
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contact us
Head of business publishing: Andy Beevers E-mail: abe@amiplastics.com
Editor: Chris Smith E-mail: cs@amiplastics.com
Consulting editor: Noru Tsalic E-mail: nt@amiplastics.com
Designer: Nicola Crane
Advertisement manager: Claire Bishop E-mail: claire@amimagazines.com
Direct tel: +44 (0)20 8686 8139
May 2014 | PIPELINE COATING 3
PIPELINE COATING | May 2014 4
news
Aegion Q1 revenues ahead 35%
$217m attributed to the
Brinderson business unit. Total
group order backlog stands at
749m.
Aegion has recently secured
a number of high value
contracts. In March, the City of
Baltimore in the US awarded it
a $10m contract covering the
application of Insituform CIPP
linings to around seven miles
Aegion Corporation reported a
35.5% increase in revenues for
the rst quarter of 2014, up to
$306.2m due largely to the
rst contribution from its
Brinderson oil and gas service
group acquisition.
The company also, however,
reported gains in its Commer-
cial and Structural and Waste
and Waste Water business
ShawCors Bredero Shaw pipe
coating division has won a
$70m contract from BP
Exploration (Shah Deniz) on
behalf of the South Caucasus
Pipeline Company for coating
the South Caucasus Pipeline
(SCP) Expansion.
The contract involves
The SCP Expansion Project
is intended to expand the
capacity of the existing SCP
system to accommodate
additional gas throughput from
the Shah Deniz Stage 2
development in the Azerbaijan
sector of the Caspian Sea.
www.brederoshaw.com
Bredero Shaw to coat SCP Extension
units totalling $5m. However,
its Energy and Mining division
was slightly impacted by
decreased sales in in its
industrial lining activities and
a slowdown in Canadian
pipeline construction and US
pipe coating.
The Energy and Mining
division had an order backlog
of $416m at the end of March,
coating approximately 491km
of predominately 48-inch pipe
with a three-layer polyethylene
(3LPE) external anti-corrosion
coating and applying internal
ow coatings. Coating work is
expected to commence in 2014
and be completed in late 2015,
said the company.
Developers of the Donlin
Gold project in Alaska,
Barrick Gold and Nova Gold,
have led for a right of way
for a 315-mile natural gas
pipeline that will run from
Cook Inlet to the mining site
at Crooked Creek, according
to a report in the Anchorage
Daily News.
www.donlingold.com
Canadian crude oil exports
by rail increased by 83% in the
nal quarter of 2013,
compared to the same period
in 2012, according to data
from the countrys National
Energy Board (NEB). Volume
exports were up from 1.16m
m
3
in Q4 2012 to 2.14m m
3
in
Q4 2013.
www.neb-one.gc.ca
Europipe has placed an
order worth around $50m
with Bredero Shaw for
concrete weight coating of
Line 1 of the South Stream
Offshore Pipeline that will run
beneath the Black Sea
between Russia and Bulgaria.
The contract, will be carried
out at Leith in Scotland.
www.europipe.com
news in brief
Saipem contracted to build the
rst South Stream pipeline
of small and medium diameter
wastewater pipelines.
In late April, the companys
Corrpro subsidiary won a
$6.6m contract to provide
engineering and cathodic
protection services for 700
onshore well casings in the
Dukhan oileld in Qatar by
Qatar Kentz.
www.aegion.com
Saipem has won the contract
to build the rst of the four
South Stream offshore
pipelines designed to carry gas
from Russia to Bulgaria
beneath the Black Sea.
The contract, valued at
around E2bn, includes design
and installation of the subsea
pipeline plus the shallow water
sections, shore crossings,
landfall and associated
facilities for all four pipelines.
Construction will com-
mence at the end of 2014 and
is expected to continue to the
third quarter of 2015.
The pipeline will be laid by
Saipem 7000 (pictured), the
companys state-of-the-art
J-Lay vessel for ultra-deep
water applications, and
Castore Sei. Parts of the South
Stream pipeline will be laid at
depths of 2,200m, according to
Saipem.
www.saipem.com
news news
Canadas National Energy
Board (NEB) has approved
Enbridge Pipelines plans to
reverse a section of its Line 9B
pipeline and to increase capac-
ity of the Line 9 pipeline to
carry heavy crude to reneries
in Ontario and Quebec.
NEB has given approval to
reverse the 639km section of
Line 9B between North
Westover in Ontario and
Montreal in Quebec (it already
had gained approval to reverse
Line 9A between Westover and
Sarnia). The approval will
increase the overall capacity of
Line 9 between Sarnia and
Montreal from 240,000 to
300,000 barrels a day.
The decision means
Enbridge will be able to run all
of Line 9 in an eastward
direction, allowing it to
transport crude oil from
western Canada and the US
Bakken region to Ontario and
Quebec rening operations.
Bringing a new, reliable
supply of competitively-priced
crude oil to respond to the
needs of Quebec-based
reneries will protect more
than 4,000 jobs, sustain a
vibrant petrochemical industry
and strengthen the economy,
said Enbridge president and
CEO Al Monaco.
www.enbridge.com
NEB approves Enbridge
Line 9B reversal scheme
Marathon Oil Norge has
awarded the contract for
extension of subsea infrastruc-
ture on the Alvheim eld on
the Norwegian Continental
Shelf to Technip. The work
includes installation and tie-in
of spools and protection
covers, as well as installation
of one manifold.
www.marathonoil.no
www.technip.com
The month-long interrup-
tion to the Cano Limon
pipeline in Columbia
following a terrorist bomb
attack has cut the countrys
daily crude oil output by
72,000 barrels (some 7%),
according to data from the
state oil company Ecopetrol
reported by Reuters. The
pipeline carries oil from the
Cano Limon oileld to
Columbias Caribbean coast.
www.ecopetrol.com.co
Defective pipeline coatings
have been blamed for a
series of leaks that have
halted production from the
Kashagan oileld in Kazakh-
stans Caspian Sea, according
to Reuters.
It reports sources
attributing the problems to
incorrect coating selection
for the sour gas product and
potentially incorrect storage
prior to installation. Produc-
tion may not restart until
2016 said Reuters.
www.reuters.com
news in brief
Marathon awards
Alvheim contracts
Now in its 7th year, Pipeline Coating 2015 will once again
provide a unique forum for the worlds leading pipeline
contractors, operators, pipe mills and pipe coaters,
engineers and speciers, researchers, raw materials and
machinery suppliers to debate the latest pipeline
protection technology and worldwide industry trends.
Pipeline Coating 2015
The international conference on pipeline protection,
coating technology, materials and markets
17-19 February 2015,
Austria Trend Hotel Savoyen, Vienna, Austria
Organised by:
Applied Market
Information Ltd.
To nd out more about speaking, attending, exhibiting or sponsoring this market leading
event, contact the conference organiser Sabine Prack, Email: sp@amiplastics.com;
Tel: +44 (0)117 314 8111. Or visit the conference website: http://bit.ly/PC_2015
IMAGE: WASCO COATING GROUP
PIPELINE COATING | May 2014 6
news
TransCanada plans Eastern Mainline expansion
Technip reported a 23%
increase in year-on-year
revenues to 2.47bn for the
rst quarter of 2014, with
gains made in both the subsea
and onshore/offshore sectors.
Chairman and CEO Thierry
Pilenko (pictured) said its
subsea operations had
beneted from the start-up of
commercial production at its
exible pipe facility in Brazil,
as well as ongoing work in the
Gulf of Mexico; onshore/
offshore had gained from the
AMI publishes the 9th Element
Oileld conference programme
commencement of several
new projects.
Order intake has been very
strong in subsea with over
2bn of new orders, including
a very large project in Angola,
said Pilenko. In the offshore
segment, a number of smaller
and medium-sized projects,
for example a medium sized
EPC in Brunei or technology
FEEDs, contributed to over
700m of new orders.
Q1 subsea orders included
36km of exible risers and
owlines and 195km of pipeline
and subsea equipment for the
Jangrik eld in Indonesia.
S www.technip.com
AMI has published the
programme for the 9th
Element Oileld Engineering
with Polymers conference,
which takes place in London in
the UK on 21-23 October 2014.
This well-established event,
formerly the MERL conference
(Materials Engineering
Research Laboratory is now
Element), examines the role of
thermoplastics, elastomers
and composite materials as
components in the demanding
oil and gas environment.
Speakers at this interna-
tional conference include
technical experts from
Hoerbiger Corporation of the
US, Prymsian Surex Umbilic-
ais of Brazil, Statoil of Norway,
Swagelining of the UK, and
Technip and Total of France.
Download the full pro-
gramme and nd out more
about attending, exhibiting or
sponsoring the event click here:
http://bit.ly/ElementOEP14
TransCanada Corporation has
led a project description with
the National Energy Board of
Canada for its Eastern
Mainline Project, including
construction of up to 370km of
new pipeline.
The proposed project will
add new facilities to the
companys existing Canadian
Mainline natural gas transmis-
sion system in south-eastern
Ontario, ensuring it can
accommodate growing
demand and new supplies of
natural gas from the northeast
of the US, the company said in
a statement.
The new project results
from the proposed transfer of
a portion of the Canadian
Mainline capacity from natural
gas to crude oil service, which
is part of TransCanadas
proposed Energy East Pipeline
Project.
The new scheme proposes
construction of 370km of up to
36-inch diameter pipe together
with associated compression
facilities adjacent to the
companys existing Mainline
facilities between Markham
and South Dundas in Eastern
Ontario.
This new pipeline infra-
structure will be a vital
addition to the Canadian
Mainline system to meet the
needs of Ontario and Quebec
gas consumers, said Russ
Girling, TransCanadas
president and CEO.
S www.transcanada.com
Wood Group
acquires
Sunstone
UK-headquartered Wood
Group has acquired
Sunstone Projects, a
pipeline consultancy
company based in Calgary,
Canada, that provides
engineering, procurement
and construction manage-
ment services to the
countrys oil & gas industry.
Wood is paying
CN$14.5m for Sunstone,
which employs 70 staff and
generated sales of around
CN$21m in 2013. The
company will be rebranded
as Wood Group Mustang and
will be run by the existing
management team under
president Barry Bauhuis.
The Canadian pipeline
system is expected to
expand to ensure access to
markets for oil and gas
produced in western
Canada, said Wood Group
Mustang president Steve
Knowles. The acquisition of
Sunstone will strengthen our
ability to provide our clients
with services in this area.
S www.woodgroup.com
Technips Q1 sales up by 23%
PIPELINE COATING | May 2014 8
news
Arctic piling
pipes by
OMK
TMK IPSCO, the US Division of
Russian pipe manufacturer
TMK, is reducing operating
hours at its plants at Blythe-
ville in Arkansas, Camanchein
Iowa and Wilder in Kentucky. It
will also idle its 8-inch welded
pipe mill at Wilder.
The company says operat-
ing hours will be reduced by
around 30% in total in a
response to low cost imported
products.
We have seen intense
pressure from low-priced and
TMK IPSCO cuts back at
US welded pipe units
Russias United Metallurgi-
cal Company (OMK)
delivered the nal batches
of custom coated steel
pipes for pile construction
on the rst three sections of
the main Arctic Circle-Pur-
pe oil pipeline in March of
this year.
OMK has delivered a
total of 99,000 tonnes of
pipes over the past two
years. The pipes 426mm
diameter with 12mm and
10mm thick walls and
325mm diameter with 9mm
thick walls were all
produced at Vyksa Steel
Works from 09G2S grade
cold-resistant steel with a
double insulation coating.
The project has been
implemented to Transnefts
specications, according to
OMK.
www.omk.ru
Global coatings group Valspar
reported a 10% increase in
sales for the second quarter of
2014 to $1.1bn.
We are pleased to report
another strong quarter of
volume and sales growth from
International testing group
Exova has appointed Stuart
Bond to the role of global
business development
manager, corrosion. Bond
joins from UK-based TWI and
has more than 25 years of
consultancy and research
experience in the oil & gas
industry. He is a member of
the Institute of Corrosion and
is a NACE Senior Corrosion
Technologist. His role at
Exova will involve identifying
new opportunities for the
companys corrosion testing
services.
People on the move
US-based radio frequency
power supply maker Comdel
has promoted Scott Johnson
from senior vice president to
president. He takes over the
Stuart Bond
leadership role at the rm
from his father Ted Johnson,
who will continue his long
involvement with the company
as chief technology ofcer.
Scott has worked in the RF
industry in design and
management roles for more
than 30 years.
Steve Orr has taken over the
post of CEO of Canada-based
Shawcor, succeeding Bill
Buckley who retires after 20
years with the company (nine
as CEO). Orr joined Shawcor as
president in September last
year and has more than 20
years of management
experience in the interna-
tional energy industry.
Aegion board director Charles
R Gordon has been appointed
Interim Chief Executive Ofcer
of the company following the
resignation of J Joseph
Burgess from his position as
President and Chief Executive
Ofcer for personal reasons.
In a statement, the company
said it will initiate a formal
search process to identify a
permanent CEO shortly.
both our Coatings and Paints
segments, said Gary E
Hendrickson, chairman and
chief executive ofcer.
Coatings saw the strongest
gains, up by 12% to $603m.
However, this was largely
accounted for by its packaging
and wood coatings activities;
industrial and coil coatings
saw mid-single digit declines
due to uneven end market
demand.
www.valspar.com
Valspar sees Q1 revenues rise
unfairly traded imports, particu-
larly welded products, for more
than a year and a half. Since the
International Trade Commission
(ITC) announced its preliminary
decision, we have seen a
considerable surge in the
import of Korean welded pipe,
said TMK IPSCO president and
CEO Dave Mitch.
Mitch said almost half of
the welded OCTG sold in the
US in 2013 was manufactured
overseas.
www.tmk-group.com
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May 2014 | PIPELINE COATING 11
Shale gas | energy markets
It has been observed many times before that energy is
the lifeblood of global economy. Reasonably priced
energy is the enabler of almost everything to do with
modern life from basic survival needs to the produc-
tion of sophisticated goods and services. But where
does that energy come from? In recent years, we have
heard and read a lot about renewable energy; does that
mean that mankind is moving away from the more
traditional sources? Well, not quite! As the data in
Figure 1 unequivocally shows, we are using more fossil
fuels than ever before.
In fact, even consumption of coal (by far the most
polluting from a climate change point of view) is still
growing. The latest available data (2012) shows that
coal accounted for no less than 30% of global energy
inputs, only slightly below oil (33%) and well above
natural gas (24%). As for renewable sources, they
accounted for a mere 2% of the worlds energetic
balance.
Fossil fuel is what overwhelmingly powers Chinas
manufacturing engine, supplying more than 90% of the
countrys primary energy. Chinas huge reserves of
easily-exploitable low cost coal supplied 68% of that
energy demand in 2012.
Main image:
Test shale gas
drilling in
Polands Lublin
basin, one of
Europes
biggest
potential shale
reserves
Source: BP
Europe needs to act on shale
But its not just China. Coal still accounts for a
signicant proportion of primary energy production in
the US (20% of the total) and even in the climate-change
conscious European Union (18%).
As for renewable sources (such as solar, wind power,
etc), in 2012 they accounted for around 2% of US primary
energy production in line with the global average. Not
so in the European Union, where the proportion of
renewables has reached about 6%. This is a fairly
meagre result, in view of the fact it was achieved in
return for huge investments which were directly or
(more often) indirectly paid by the consumers.
So why is this? For those disinclined to believe
conspiracy theories about oil companies sabotaging
tomorrows survival for todays prot, the answer is
clear: renewable technologies are still in their infancy.
Renewable technology is, by-and-large, still incapable
of delivering energy at competitive costs of production.
This does not mean renewable energy generation
technologies should be abandoned or neglected. Quite
the opposite, in fact: more work should be invested in
research and development aimed at nding innovative
solutions. A certain level of commercial-scale applica-
tion is also necessary, to provide experience and testing
Europe is lagging the world in its development of shale oil and gas.
AMI Consulting senior vice president Noru Tsalic looks at why shale
is so important and counters some of the arguments of opponents
PIPELINE COATING | May 2014 12
energy markets | Shale gas
grounds for new ideas. But the attempts at large-scale
roll-out at this stage of technological development
seem premature and a huge waste of our money. From
a climate change/CO
2
emissions perspective, more
would be gained if that money was spent replacing the
highly polluting coal that produces 18% of our energy
requirements with clean-burning natural gas.
However, it is not just about wasting money. For
Europe, there is the bigger potential risk of squandering
an even more precious and future-related resource:
Europes economic competitiveness. In the modern world,
that all-important parameter depends on three factors:
G Cost of technology;
G Cost of energy;
G Cost of access to markets.
There is, in fact, a fourth factor cost of labour but
this is rapidly losing its importance in Europe. Very little
labour is represented in the cost of producing a new
car, or the cost of providing a minute of mobile phone
conversation.
Statistics show that much of the European Union
economy is mired in semi-stagnation, while the US
economy is beginning to grow once again. According to
the latest predictions by the International Monetary Fund,
the economy of the 28 European Union countries is
expected to grow by around 1.6% in 2014 and 1.8% in
2015 and annual growth is expected to remain below 2%
until at least 2020. As for the US, its economy is expected
to grow by 2.7% this year and almost 3% next year.
Some would argue that Europe is still struggling with
the effects of the economic crisis and that economic
normalcy is bound to return sometime in the future.
But if that normalcy fails to materialise while other
regions are enjoying economic growth then it could be
concluded that something more fundamental is wrong
something that may cause the crisis to become the
new normalcy.
Japan provides an interesting case study in this
respect. Like the European Union and US, it has good
access to both technology and markets. But like the EU
(and unlike the US), it has experienced poor access to
affordable energy. The fact is that Japan has seen its
competitiveness evaporate, causing the country to
transition from the economic boom of the 1960s, 70s
and 80s to a virtual stagnation that started in the 1990s
and shows little signs of ending. Of course, the causes
are complex, but Japans disadvantage in terms of
energy costs has been in the opinion of this analyst a
major factor (Figure 2).
On the other hand, availability of cheap energy has
been a major factor in the current recovery of the US
economy a recovery driven by strong growth in the
manufacturing sector. In the US, low cost energy is a
result of growing production of shale gas and tight oil,
itself made possible by a combination of technology
progress and sensible economic management.
It could be argued that, if it is to maintain or recover
its competitiveness, Europe also needs affordable
energy. If the continent is also to reduce CO
2
emissions,
then rather than engaging in expensive renewables, it
needs to replace coal with natural gas.
Where is that gas going to come from? The North
Sea hydrocarbon reserves are gradually dwindling.
There may be many years of scraping the barrel left,
but this is not a solution for growing demand. The
Middle East and Africa can produce cheap gas but
transporting it to Europe bites deeply into any competi-
Figure 1: Worlds consumption of primary energy, by source. Values in
billion tonnes of oil equivalent. Source: BP
Figure 2:
Assessment of
regional economic
competitiveness
Pipe blasting and coating systems
Pipe handling equipment
Selmers Biesland 3 1948 RJ Beverwijk The Netherlands
telephone (+31) 251 211 999 fax (+31) 251 220 777 email sales@selmers.nl
www.selmers.nl
Design Engineering Manufacturing Installation Training Commissioning After Sales
Selmers_A4_2013.indd 1 25-07-13 12:06
PIPELINE COATING | May 2014 14
energy markets | Shale gas
tive advantage not to mention that both regions are
plagued by political instability. Russia already supplies
almost 40% of Europes imports of natural gas and,
given the ongoing conict in Ukraine, Europe is likely to
want to decrease that share rather than increase it.
The obvious solution is much closer to home. Like
the US (and China), Europe possesses large reserves of
shale gas (Figure 3). The difference is that, while shale
gas has already revolutionised the US economy and
China is decisively moving towards commercial
exploitation, very little is happening in this direction in
Europe. In 2013, the US produced more than 200bn m
3

of shale gas. China has produced in excess of 200m m
3
.
There is, undoubtedly, a strong anti-shale lobby in
Europe. Some oppose the exploitation of shale gas on
ideological grounds. Others, however, argue there are
other, more tangible, reasons why shale will not work
in Europe. One argument frequently put forward is
demography: it works in the US, some say, because the
population is much sparser there. In densely populated
Europe, however, there just isnt room to set up the
necessary facilities without huge inconvenience to large
layers of the population.
At rst glance, there appears to be some truth in this
argument. The US does have a much lower population
density, compared to Europe. But a more detailed
examination shows that shale gas is not uniformly
distributed in the US and nor is the population. The bulk
of shale gas exploitation occurs in regions which are no
less densely populated than Europe, or at least the
European countries where most of the shale gas
reserves are located (Figure 4).
An additional argument opposing shale gas exploita-
tion claims that such activity presents a severe risk of
causing earthquakes, soil pollution and aquifer
contamination, or that it will require huge volumes of
fresh water. Again, this is not borne out by the facts. An
independent study published in January 2014 by the
UK-based Chartered Institution of Water and Environ-
mental Management (CIWEM) concluded that: Com-
pared to other fossil fuels, the overall water use intensi-
ty of shale gas is low and claims by some opponents
that the shale gas industry represents a threat to the
security of public water supplies is alarmist. The same
study also noted that: Contamination of aquifersis
unlikely where shale plays exist at depth in the UK.
Of course, like many industrial endeavours, shale
gas exploitation can cause damage to the environment
and risk to health and safety if it is improperly conduct-
ed. But if we adopted an approach that blocked all
industrial activities on such criteria, then none would
ever be performed.
Some oppose shale gas exploitation on production
economics arguments and there is some merit in this.
The current production cost of shale gas in the US
uctuates between $3 and $5 per million BTU but due
to the different geology of shale and surrounding rocks
in Europe, production costs are expected to be much
higher, perhaps $8-$12 per BTU. However, Europe has
often bought natural gas at prices in excess of that
production cost, while experience and technological
progresses are likely to drive European costs down.
According to a recent study performed by Ernst &
Young: Production costs in North America have
declined markedly over time with advances in technol-
ogy and knowledge transfer gained from the experience
of large-scale production. Technologies for drilling and
fracking are not at a developmental standstill. Growing
recognition of the potential of shale resources mean
that oil and gas and oileld services companies will
invest in research and development to improve the
efciency and lower the cost of shale gas exploration
and production.
Opponents also claim that if shale gas exploitation
does result in a lowering of energy costs in Europe, this
Above:
Protestors at
Balcombe in
the UK
demonstrate
against
Cuadrillas
fracking test
drilling
Figure 3: Shale gas Total Recoverable Reserves
(TRR, 2012 best estimate) Source: EIA
Shale gas | energy markets
would decrease the incentive to achieve greater energy
efciency and develop renewable energy solutions. But
Europe is not an isolated island it is a geo-economic
region in an increasingly inter-connected world. Europe
competes with other regions. Higher energy costs will
make Europe less competitive; this will not translate to
more clean energy being used in Europe but to more
dirty energy being used in China and elsewhere.
In conclusion, while shale gas may not be a solution
for all of Europes economic issues it is certainly an
important component of that solution. However, left to
their own devices and faced with a vocal if irrational or
poorly informed opposition, politicians and bureau-
crats are likely to dither and prevaricate. It is imperative
that the Oil & Gas-related industries including the
pipe coating industry urgently mobilise to lobby
governments and to explain this issue to the public.
For further information:
Shale gas and its potential impact on the economy in
general, and the pipe coating industry in particular, are
explained in AMIs recent report on the global markets
for steel pipe coating. More information can be found
here. Or contact Noru Tsalic, Tel: +44 (0)117 924 9442,
Email: nt@amiplastics.com.
These issues will also likely form part of the
discussions at AMIs Field Joint Coating conference,
which takes place in September in Dsseldorf, Ger-
many, and will deal with all aspects of eld-applied
pipeline coatings.
www.amiplastics.com
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May 2014 | PIPELINE COATING 17
Polyethylene | coating developments
Energy markets and the energy transportation sector
are under constant change. Global forecasts show a fast
growing energy demand over the next two decades,
primarily from non-OECD countries, which will be met
by tapping increasingly challenging and remote eld
developments. Energy demand and supply centres are
becoming increasingly distant from each other. As a
result, hydrocarbon transportation will play a critical
role in the energy value chain.
Safe and reliable hydrocarbon transportation
requires high performance anti-corrosion coatings.
Pipeline integrity specialist Bredero Shaw has devel-
oped a new pipeline protection platform launched
earlier this year under the SureBond name. The new
system uses a functionalised polyolen topcoat resin
that eliminates the need for an adhesive layer while
providing enhanced real-world performance.
Global challenges
The starting point for the project was to research the
global view of the current challenges faced by pipeline
operators, which was used to frame out the functional
requirements. This rst step in the standard Bredero
Main image:
First application
of the SureBond
100 coating
technology is
the Audex
Rotary oil
terminal project
at Fujairah in
UAE
Functionalised
approach
to pipeline
protection
Shaw technology development process typically reveals
common clusters of requirements, spanning geogra-
phies and historically-used coating types.
It is well known in the pipeline industry that the
quality of application of a coating has a dramatic impact
on long term system performance so it is important to
choose a reputable coating service company. For those
that do, and who are satised with the current
performance levels of existing pipeline anti-corrosion
coating systems, the overwhelming feedback focused
on the eld joint as a primary root cause of integrity
concerns.
Further improving the performance of the anti-cor-
rosion main line pipe coating system will have only a
marginal impact on overall pipeline system perfor-
mance when the weakest spot, which is known to be
located around the eld joint, remains unaddressed.
It was clear that development of a next generation
coating would have to not only exceed current perfor-
mance levels as measured against specications
(temperature rating, impact, cathodic disbondment,
bending, thermal cycling and the like) but also to help
mitigate eld joint concerns.
Launched this year, Bredero Shaws SureBond 100 coating system
uses functionalised PE to simplify coating structure while offering
improved mechanical and eld joint performance.
Cedric Oudinot explains more
L
PIPELINE COATING | May 2014 18
coating developments | Polyethylene
Process development
Bredero Shaws research scientists were presented with
a mandate based on this customer feedback and
allocated over two years to develop and evaluate the
optimal formulation platform that would meet clients
needs. The research team nally settled on a polyolen
matrix (primarily PE) with a novel and patented
molecular design which gives SureBond

performance
similar to typical 3LPE systems yet does not require the
often problematic adhesive interlayer. The coating
construction is shown in Figure 1.
This novel approach is based on a tightly controlled
set of chemical reactions that take place between the
topcoat and the non-fully cured FBE substrate during
application. The result is a fully fused, chemically
bonded system with exceptional performance. The
functionalised PE blend results in a topcoat that exceeds
3LPE performance requirements due to creation of a
tough secondary network in the polymer while offering
an improved cutback substrate for eld joint application.
The next stage in the development process was to
scale the laboratory formulation to an industrial solution
ready for the factory oor. This additional twelve month
programme pulled in Bredero Shaws extensive plant
network, global engineering expertise and material
science expertise to ensure a reliable coating solution
that meets stringent and proven capability require-
ments. Multiple trials were held at several manufactur-
ing facilities to bring together fundamental knowledge
and operational expertise within a cross-functional
initiative designed to compress time-to-market. As part
of this programme, new plant equipment had to be
designed to accommodate the nature of the topcoat,
which reacts with a non-gelled FBE substrate, without
impacting on plant accreditation or line speed perfor-
mance. Figure 2 shows an inline curing oven developed
as part of the industrialisation process.
Performance benets
Over the course of these process trials samples were
sent to globally recognised testing labs across several
geographies to independently validate the enhanced
performance observed during the research stage. The
results showed that the engineered formulation
comfortably exceeded specications such as ISO21809-
1. The SureBond

coating has excellent barrier proper-
ties, which minimises the diffusion of corroding species
such as oxygen and water to the coating/steel interface.
Consequently, adhesion to the steel is very stable in
service environments. The system shows excellent
performance in 28 day cathodic disbondment tests at up
to 95C compared to equivalent systems, working
synergistically with cathodic protection systems to
Figure 2: The
in-line curing
oven where the
SureBond

100
curing process
is initiated
Figure 1: Illustrative thickness models
of SureBond compared to 3LPE and
DFBE coating systems
May 2014 | PIPELINE COATING 19
Polyethylene | coating developments
provide long term pipeline protection.
Another benet of the SureBond

system

is that
mechanical properties such as impact resistance,
hardness and exibility all of which are directly linked
to installation performance of the coating system in the
eld exceed those of equivalent 3LPE systems. Impact
resistance is so improved (
>
12J/mm) that the sug-
gested topcoat thickness for a SureBond-based system
is roughly half of that of an equivalent 3LPE.
While SureBond was designed to meet existing 3LPE
specications, its adhesive-less design results in a
positively distinct performance in adhesion testing,
where the topcoat cohesively fails. This provides a
failsafe mechanical and moisture barrier that further
protects FBE. This cohesive failure behavior occurs even
at high operating temperatures and is shown in Figure 3.
The interlocking chemically bonded system also
helps spread strain across the total thickness, which
results in very good exibility performance at much
lower temperatures than alternative anti-corrosion
systems. Bredero Shaw testing has shown SureBond
yields a 2.5 ppd system bend test at -50C and passes
a 2.5 ppd topcoat bend test at -70C without cracking.
This opens up a variety of new installation applications,
including previously unavailable cold bending capability
or artic installation conditions.
The coating system design also offers minimal
component thermal mismatch and reduces shrinkage
from the melt to solid phase, which eliminates issues
with residual stress delamination during storage or
eld joint application. This results in outstanding
thermal cycling properties, showing no disbondment in
over ten -70C to +100C cycles. Even more aggressive
thermal shock testing with -70C to +100C shock
cycles and no thermal equilibrium also resulted in no
disbondment.
Given the performance data, Bredero Shaw is
condent a SureBond pipeline will offer the asset owner
a safer operating window and provide operators with a
higher level of condence even after unexpected process
upset, such as a sudden gas line depressurization,
which could otherwise result in coating failure. This
advanced thermal stability performance also delivers a
higher level of pipeline protection in permafrost settings.
Field joint performance
As discussed earlier, a key design parameter for the
SureBond topcoat was to deliver enhanced eld joint
performance. The system

is based on a blend of reactive
and functionalised polyethylene. The reaction between
the components begins during the extrusion process
and continues in the inline post cure oven after the
extrusion step, locking the polymer networks in place.
However, the system retains a small amount of reactivity
from the adhesion promoter and the functionalised
polyethylene, which reacts at the temperatures typically
reached during eld joint installation. This small amount
of residual reactivity enhances the chemical bond to the
adhesive group or epoxy group in a typical eld joint
solution. In addition, SureBond exhibits a substantially
higher surface energy than the typical polyethylene
grades commonly used in 3LPE application, as shown in
Table 1. Higher surface reactivity translates to greater
chemical afnity and hence a stronger bond to the eld
joint material.
Global availability
Bredero Shaw secured and executed its rst SureBond

100 application at its Ras-Al- Khaimah, facility in UAE in
January of this year. The coating system was applied to
6, 18, 24 and 30-inch pipes for the Audex Rotary oil
terminal project at Fujairah. The SureBond product will
be rolled out across the companys global coating
facilities over the coming months.
www.brederoshaw.com/Surebond
About the author:
Cedric Oudinot is global product line manager for
anticorrosion and internal coatings at Bredero Shaw in
Houston, US. Oudinot graduated in engineering in
France, gaining a chemical engineering masters degree
and an MBA in the US. He has more than a decade of
experience in commercial and technical roles in the
international oil & gas industry. Oudinot joined Bredero
Shaw in 2010, taking on his current role in 2012.
Figure 3: A
SureBond 100
peel test under
way (left) and
example of the
cohesive failure
(right) resulting
in peel
performance
above 4N/mm
at 80C
Table 1: Typical surface energy results (in mJ/m/
dynes) for different coating systems
Polymer material Surface Energy
3LPE Surface 34-36
3LPP Surface <30 (28-29)
SureBondTM 44-46
Epoxy 54-56
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May 2014 | PIPELINE COATING 21
North America | pipelines
Vital pipeline projects are facing
intense and delaying scrutiny in the
US, to the benet of rail, barge and
road. Nicholas Newman explains why
pipelines will, in the end, win out
One of the biggest challenges facing the North
American energy industry is how to deliver the huge
new shale oil and gas ows made possible by new
technologies such as horizontal drilling and fracking in
a safe and efcient manner. The novel nature and
location of much of these new hydrocarbon products is
just part of the problem, the energy industry also faces
a proliferating range of environmental, regulatory and
political pressures.
Selecting a delivery option can no longer be deter-
mined by a simple cost- benet analysis. The choice of
pipeline, road, rail, barge or coastal tankers will depend
on the interplay of safety issues, operational and capital
costs, as well as environmental and regulatory
considerations.
In the aftermath of recent large scale accidents,
there appears to be growing public, political and
regulatory concern over the absolute and relative safety
of different transportation modes for oil and gas
industry products. Examples include the oil train
railway explosion in July 2013 in Lac-Megantic in
Quebec in which 47 people died and the explosion in
February 2014 on a major natural gas pipeline in
southern Kentucky, which led to a forced evacuation of
residents. Incidents such as these have sparked
growing public and political concern over new energy
transport projects, most visible in public protests
against TransCanadas Keystone XL project and the
The politics of
US pipelines
mile-long crude oil trains moving through cities such as
Philadelphia to the reneries on the Delaware River on
the east coast.
The fundamental question being asked today is: How
safe and reliable are pipelines? Given that some 40% of
US oil pipelines were constructed in the 1950s and 1960s
and 15% of the countrys 281,000km network even
earlier, according to data from the Association of Oil Pipe
Lines, it is a fair question to ask. However, reliability is
less a question of age and more one of pro-active and
effective maintenance, argue pipeline operators.
The age of the pipe shouldnt make any difference,
says Pat Denial, CEO of pipeline operator Enbridge.
That view is supported by US Department of Transpor-
tation safety statistics (Figure 1), which show that
pipelines incur fewer spillage incidents and personal
injuries than either road or rail. US casualty statistics
PIPELINE COATING | May 2014 22
pipelines | North America
for the period from 2005 to 2009 show that oil pipelines
are around 70 times safer than truck transportation (the
latter resulted in the deaths of four times as many
people over the period despite carrying only a fraction
of the fuel shipments).
According to US government statistics, pipelines are
the primary means of transporting crude oil, petroleum
products and natural gas across the country with some
70% of crude oil and petroleum products transported by
pipeline on a ton-mile basis. Domestic tanker and barge
trafc accounts for 23% of oil shipments, road tankers
4% and rail tankers 3%. Currently, all natural gas in the
US is transported by pipeline.
Pipelines are also the safest transport means. Last
year the Congressional Research Service (CRS) 2014
report US Rail Transportation of Crude Oil: Background
and Issues for Congress presented data showing
pipeline transportation is safer than road, rail or barge,
when measured by incidents, injuries and fatalities. The
report also noted that many road and rail incidents are
unreported, suggesting the safety margin of the pipeline
industry may be even larger.
Cost considerations
Of course, cost is also a key consideration. Moving large
amounts of crude oil along the proposed 1,179-mile
Keystone XL pipeline (Figure 2) will cost around $7 per
barrel, according to the US State Department. Pipeline
operator Enbridge charges a tariff of $13 per cubic
metre for travel of light crude along the 800 mile
pipeline linking Kerrobert Station in Saskatchewan to
Superior.
For reneries located next to major navigable
waterways, such as the Atlantic Seaboard or Gulf Coast,
shipment by barge is cheaper than rail or pipeline.
Barges are about 30% cheaper than rail, according to
Steve Clark, commercial manager of shipping and
logistics agency GAC Shipping USA.
Clark quotes a day-rate of around $8,500 for a
two-barge tow, each carrying 30,000 barrels of West
Texas Crude oil. That means the 14 day-round trip of
600 nautical miles from Corpus Christi to reneries in
New Orleans works out at around $4 per barrel. An
American Petroleum State Class coastal tanker with a
carrying capacity of 330,000 barrels of cargo capacity
would cost around US$54,000 a day, equivalent to $2.3
per barrel for the same shipping duration. It is,
perhaps, fortunate for pipeline operators that the US
Jones Act designed to protect US shipping from
foreign competition in home waters remains in place
as it is highly likely barge rates would be even lower if
open to global competition.
In comparison, transporting crude oil over the 800
miles by rail from the Bakken oil elds to the Gulf Coast
will cost between $15.5 to $31 per barrel, according to
the US State Department. Leasing costs for a class
DOT-111 rail tanker carrying 31,809 gallons can reach
$2,500 a month, excluding the additional cost of
accessing the rail network and the use of rail operator
services (Figure 3). However, the North American rail
network is much more extensive than the pipeline
network and this presents the opportunity for producers
to exploit market conditions and sell to the highest
bidders at any given time.
Obtaining meaningful investment gures for
comparison of the different transport modes is difcult.
Figure 1: Comparison of petroleum incident rates by transport mode
Transport Incidents per Average billion
mode billion miles ton-miles per year
Barge/domestic tanker Data not available Data not available
Road 19.95 34.8
Rail 2.08 23.9
Hazardous Pipeline 0.58 584.1
Natural Gas Pipeline 0.89 338.5
Source: US Department of Transport: Bureau of Transportation Statistics 2013
Figure 2: It will
cost around $7
a barrel to
move oil using
the 1,179-mile
Keystone XL
pipeline
Source: TransCanada
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Testing, calibrating, advising
PIPELINE COATING | May 2014 24
pipelines | North America
Rail has cheaper capital costs than pipelines but costs
more to operate, says Steven Paget, director of energy
industry nancial and investment service provider
FirstEnergy Capital.
The capital cost of pipeline construction is certainly
eye-watering. For example, TransCanada estimates the
capital cost of constructing the Keystone XL Phase Four
1,179-mile (1,897 km), 36-inch-diameter crude oil
pipeline at $7.6bn.
Oil shipments by rail have ballooned with the
development of new shale oil elds in North America.
Carrying oil by rail requires dedicated oil tank rail cars
costing between $120,000 and $175,000 each, according
to industry experts. Warren Buffets BNSF railway
recently announced plans to buy 5,000 new tank cars to
transport crude oil, placing an estimated investment
cost on the project of $1bn. In addition, there is the cost
of locomotives and track to consider. A single track
freight line with a few locomotives and simple signalling
running across a at, geologically sound, sparsely
populated landscape might be built for as little as $2m
per kilometre, including electrical and mechanical
equipment, according to railway-technical.com. A typical
diesel locomotive costs between $1.75m to $2.3m.
Turning to tanker barges and coastal freighters, a
second-hand 2,760 ton river tanker with a cargo
capacity of 2,736 ton/3,684 cbm may cost around
$600,000. As for coastal fuel carriers, coastal tanker
operator American Petroleum is currently building four
State Class vessels, each with a carrying capacity of
330,000 barrels, at a total cost of $214m.
According to Haartztankersales.com, a road tanker
tractor unit and transport trailer with a capacity of
43,000 litres will cost around $143,000 to buy, or around
$1,683 per week to lease. These costs do not take into
account the public cost of trafc jams, crumbling roads
and the not insignicant cost of road repairs, mainte-
nance and upgrades to cope with new oil trafc. The
Texas Legislature, for example, has budgeted $450m to
cope with new shale oil being moved by road from the
Eagle Ford formation.
Funding the expansion of North Americas energy
infrastructure is becoming increasingly difcult as the
traditional lenders banks adapt to increased capital
ratio requirements. The new sources of infrastructure
nance that are stepping in to ll the gap include private
equity rms, pension funds and insurance companies
seeking a regular income. KKR, for example, plans to
invest $2bn in infrastructure, while Calpers is planning
to increase its funding for infrastructure from 2% to 3%.
A recent as a decade ago, the big issue In North
America was to simply ensure oil and gas was delivered
to the people that needed it and, in general, energy
companies faced very little resistance to projects that
helped accomplish this goal . As FirstEnergys Paget
says: Seven years ago, there was almost no permitting
risk around new energy transportation initiatives. Now
permitting risk is probably the single largest risk facing
new energy transportation projects. Investors can no
longer assume that a commercially secured energy
project will be permitted.
Changing priorities
Priorities have changed for both energy transport
regulators and operators. The main safety issue in all
cases is to avoid a product release, particularly one onto
third-party property, Paget says. As a consequence,
construction plans for new pipelines are being exam-
ined closely by environmentalists, landowners and
indigenous First Nations seeking to prevent or delay
projects.
TransCanadas Keystone XL pipeline, which crosses
the Canadian-American border and so has to undergo
detailed environmental impact assessment, is perhaps
the prime example of how long a decision can be held in
the balance. In the latest in a long-running series of
delays, President Obama has deferred a nal decision
until after the next election. However, the proposed
610-mile $2.6bn Sandpiper pipeline, which is designed
to transport oil from the Bakken region to Lake
Superior, falls under state jurisdiction so requires
neither the Presidents permit nor a comprehensive
environmental impact statement.
Pipeline operational regulation is also an issue as far
as opponents are concerned. At present, day-to-day
operational regulation of US pipelines lies in the hands
of a patchwork of federal and state agencies that some
argue are inadequate and lacking in public scrutiny. At
Federal level, the US Department of Transports
Pipeline and Hazardous Materials Safety Administration
(PHMSA) subjects only 7% of natural gas lines and 44%
of all hazardous liquid lines to regular and rigorous
inspection, leaving it to the discretion of pipeline
companies to manage their assets.
A recent US Government Accountability Ofce (GAO)
report estimated that of the roughly 230,000 miles of
gathering lines that connect wells to process facilities
Figure 3: Comparison of North American transportation costs by mode
Transportation mode Cost per barrel Distance
Pipeline $7 per barrel
1,179-mile
Keystone XL pipeline
Rail $15.50 to $31 per barrel 800 miles
Barge $4 per barrel. 600 nautical miles
Road Tanker Details not available Details not available
Sources: US DOT, AAR, US Coast Guard
May 2014 | PIPELINE COATING 25
North America | pipelines
or larger transmission lines, only 24,000 miles are
federally regulated. The National Wildlife Federation
argued in a 2012 report After The Marshall Spill:
Pipelines in The Great Lakes Region that federal laws
are inadequate in a number of respects and that state
legislatures have not covered the gaps.
Until this year, the US public had no free right to access
the industry standards incorporated into the regulations.
There is also no opportunity for the public to comment on
the safety of individual lines during their construction or
operation, except when an operator applies to obtain a
waiver from general requirements. Furthermore, the
public does not have an opportunity to comment on
operators spill response plans. Public scrutiny and access
to requisite information is constrained.
As US oil and gas production has grown, US pipeline
plans have become a political hot potato. Despite a
string of high prole accidents and the growing
effectiveness of anti-pipeline pressure groups, US
public opinion remains mixed. In September 2013, Pew
Research Centre carried out a survey of public attitudes
towards the Keystone XL pipeline project. It found 65%
in favour; 30% against, and 5% dont knows. However, it
also found a sharp division by political views. An
overwhelming majority of Republicans (82%) favoured
construction of the pipeline, as did 64% of independ-
ents, but only around half of Democrats (51%). Pipeline
developers are having to take such ndings into account
the public has to be won over and strong political
support gained if large pipeline projects are to be
realised in a democracy.
Rail has beneted from booming shale oil extraction
and public opposition to new pipelines. However, a
surge in accidents of rail oil-tanker trafc has attracted
the attention of the regulatory authorities and a
tightening of regulations.
State emergency planning agencies are responsible
for co-ordinating emergency response during a major
accident. In addition, there are Federal-level mandatory
requirements. First, the Department of Transport
requires rail cargoes to be tested for classication
purposes. Second, the PHMSA has introduced new
safety design standards for crude oil rail tanker
specications to reduce the risk of explosion caused by
derailment and collision. The Federal Rail Administra-
tion has also begun unannounced spot inspections of
crude suppliers and transporters.
Public anxiety has been fuelled by rail accidents
involving oil. In North Dakota, for example, the oil train
collision of December 2013 was the fourth in just six
months. Meanwhile, in Washington State the frequent
Figure 4: North
American Class
1 railroad
network
Source: Wikipedia Commons
US Renery
receipts of
crude oil by
mode of
transportation
Source: Prepared
by CRS; data from
EIA, Renery
Capacity Report,
Table 9, June 2013
Notes: Some shipments may
involve multiple modes, such
as rail to barge. This gure
indicates only the mode used for
the last leg of such shipments.
pipelines | North America
mile-long crude oil trains are reported to be causing
trafc chaos at rail crossings. It is ironic, in fact, that
growing public opposition to new pipeline construction
is contributing to oil producers switch to trains while
the evidence shows that pipelines are safer.
As for road and water movements, the Federal
Highway Administration and the US Coastguards
regulate road oil tankers and water trafc respectively.
Neither transportation mode has seen particular public
pressure to tighten safety standards or restrict usage
- road oil tankers are perceived by the US public as just
another part of day-to-day trafc on Americas roads,
while barges benet from a general perception of
safety. This would suggest that road and water trafc
may nibble away at demands for new pipeline capacity
along selected routes.
Pipelines are, in many respects, the victim of their
own effectiveness. It is undoubtedly much easier to
mobilise public opposition against one big project than
to effectively challenge many small ones. But despite
the highly organised and vociferous opposition to the
construction of new pipelines and the competition
from rail, road and water the demand for new pipeline
construction will inevitably grow to accommodate the
vast expansion in shale gas and oil output.
Inevitably, some pipeline projects will be delayed or
will fail, but the majority will be built. Pipelines simply
offer higher investment returns, superior safety and
better environmental performance over long distance
rail and road tankers, while barges can provide only
limited competition in large volume long distance oil
and gas transportation.
Rail has gained
from the delay
in approving oil
pipelines
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Real co-extruded 3-ply tape system.
No risk of spiral corrosion compared
to 2-ply tapes.
Passes class B 50 according to
EN 12068.
Compatible with mill coatings from
PE, PP, FBE, PU, CTE and Bitumen.
Designed for max. temperatures up
to 85C (185F).
Outstanding tape exibility
Elongation at break.
Very cost efcient and easy
application with excellent mechanical
and corrosion protection.
Tape system total thickness 2,0mm.

product
DIN
B 50
Real co-extruded 3-ply tape system.
No risk of spiral corrosion compared
to 2-ply tapes.
Exceeds the requirements of class
C 50 accroding to EN 12068.
Compatible with mill coatings from
PE, PP, FBE, PU, CTE and Bitumen.
Designed for max. temperatures up
to 85C (185F).
Maximum mechanical protection
combined with outstanding tape
exibility.
Tape system total thickness 3,2mm.

product
DIN
C 50
PIPELINE COATING | May 2014 28
project | Field-applied coating
Denso wins contract to
supply 2.4m square metres
of corrosion protection
products for Indian Oil
Corporations pipeline
rehabilitation programme
Indian Oil Coporation (IOCL)
the largest pipeline operator
in India has selected
tape-based coating technology
from Germanys Denso as part
of the ongoing rehabilitation of
its more than 11,000km
network of oil, petrochemical
and gas pipelines.
Denso is to supply coating
materials to protect more than
2.4m m
2
of IOCL pipelines,
which will be rehabilitated while
in operation. The system
tendered by the German
company comprises its
Densolen AS39P/R20HT
combination of a three-ply inner
and a two-ply outer polyethyl-
ene/butyl tape, which is claimed
to offer very good technical
performance and easy
application in the eld.
Parts of ICOLs pipeline
network have been in continu-
ous operation for more than 40
years. Denso Germany says it
has previously supplied more
than 2.6m m
2
of the Densolen
AS39P/R20HT Tape System to
IOCL for rehabilitation
operations. This latest 2.4m m
2

contract will be fullled in
batches over the period from
2014 and 2015 and will be used
to rehabilitate around 320km
of oil pipeline.
IOCLs requirement for
pipeline rehabilitation is that
the coating should provide
protection from corrosion for
at least a further 40 years. The
companys technical commit-
tee is convinced the three-ply/
two-ply polyethylene/butyl
tape system technology can
deliver this performance,
according to Denso.
Denso says its Densolen
corrosion protection tapes and
tape systems been used
successfully in many pipeline
projects worldwide and are
protecting more than 100m m
2

of pipelines.
The Densolen AS39P/
R20HT system is a two-tape
coating solution comprising a
self-amalgamating inner wrap
applied over a layer of
Densolen primer. Denso says it
is capable of continuous
operating temperatures of up
to 50C and carries a C-50
stress class rating. The system
comprises two layers of inner
wrap tapes and two layers of
outer wrap tapes, which
results in a total protective
layer thickness of 2.6mm.
IOCL is Indias largest
company reporting total
revenues of more than
INR4,700bn (around E58bn) for
the 2012/13 nancial year. It is
the highest ranked Indian
company in the Fortune Global
500 listing, ranked in 88
th

position (just ahead of Procter
& Gamble).
IOCLs 11,214km of
pipelines carries more than
200,000 tonnes of oil and 10m
metric standard cubic metres
of gas each day. The company
has 14 new pipeline projects
under development represent-
ing a total investment value of
INR6.7bn ($830m). Altogether,
these projects will expand its
transport capacity by a further
16m tonnes a year.
Planned projects include
the 700km Paradip-Haldia-
Budge Budge-Kalyani-Dur-
gapur and 400km Ennore-
Trichy-Pondicherry LPG
pipelines, the 295km Sangan-
er-Bijwasan naptha pipeline,
and the 120km Cauvery Basin
Renery to Trichy pipeline.
Germany-based Denso has
been manufacturing corrosion
prevention and sealing
technology products since
1922. Since the introduction of
its rst passive corrosion
prevention for pipelines the
petrolatum-based Denso-Tape
in 1927 the company has
developed a wide product
range including Densolid liquid
coatings, Densit sealing tapes,
Dekotec heat shrinkable
sleeves and Densolen
polyethylene/butyl tape
systems.
www.denso.de
Application of DENSOLEN
AS39 P/ R20HT at
IOCL in India
Denso secures major Indian
rehabilitation contract
BASF Performance Materials provide customized
solutions for the most challenging conditions onshore
and offshore. From foam breakers, rock shields to
anti-corrosion and thermal insulation coatings we design
high performance, reliable solutions. Oil and gas pipelines
navigate the toughest terrain, on land and in subsea
environments. And you can count on absolute protection
for pipes, safety for workers and sustainability for the
natural world. Because at BASF, we create chemistry.
www.polyurethanes.basf.us/oilandgas
that makes
pipelines
love extreme
conditions.
We create
chemistry
The 3rd edition of AMI
Consultings study Steel
Pipe Coating the Global
Market is is now
complete and available for
immediate subscription.
This 234-page study
comprises a detailed
quantitative and qualitative
analysis of the world market for steel pipe coating. It
considers demand, supply, raw materials, etc, and
includes forecasts through to 2016.
These are very interesting times in energy and
energy-related industries. While oil remains important
in the global energy balance, markets are moving
increasingly towards gas not just in Europe and North
America, but in Asia as well. Natural gas is becoming
a hugely important resource, to be traded globally.
Pipelines are playing a crucial role in this
development. Pipelines are needed not just to
gather, transport and distribute the gas, but also to
connect LNG import and export terminals, which are
mushrooming around the globe. Pipeline-related
industries are, therefore, likely to beneft from this
process. Steel pipe coating is likely to be among the
top benefciaries: as new pipelines tend to operate
under harsher conditions in terms of temperature,
pressure and external environment, coating is
becoming more demanding, more sophisticated and
hence more valuable.
There are additional
drivers of growth
appearing on the
horizon: the scarcity of
potable water in many
regions of the globe will
increasingly have to be
tackled through either
desalination or long-
range water
transportation with pipelines playing an important
role in both; power-plant produced carbon dioxide
will increasingly be captured, transported through
pipelines and stored.
Changes are also taking place on the supply side of
the steel pipe coating market. The previous editions
of this report have correctly forecast a consolidation
trend. This trend which has meanwhile become
apparent to everybody is set to continue with new
twists and turns, as is the competitive battle
between the two major business models: integrated
pipe mills-coating yards versus independent coaters.
The 2013 edition of the report analyses all of these
trends and their likely trajectory into the future. The
234-page report contains 88 data tables, 8 charts
and 95 exhibits. Subscribers receive two printed
hardcopies of the report and a CD containing a read
only pdf version, as well as a set of spreadsheets
with the underlying data. To receive a detailed
proposal, contact Mr Noru Tsalic at nt@amiplastics.
com or +44 117 924 9442.
JUST PUBLISHED
Steel Pipe Coating
The Global Market
(Third Edition)
For more details about this report or to request a detailed proposal, contact:
Noru Tsalic, Senior vice president AMI Consulting.
Email: nt@amiplastics.com. Phone: +44 (0)117 924 9442
Mail: Applied Market Information, AMI House,
45-47 Stokes Croft, Bristol BS1 3QP, United Kingdom AMI CONSULTING
STEEL PIPE COATING
THE GLOBAL MARKET
Third Edition
2013
STEEL PIPE COATING
THE GLOBAL MARKET
Third Edition
2013
STEEL PIPE COATING
THE GLOBAL MARKET
Third Edition
2013
www.amiplastics.com
May 2014 | PIPELINE COATING 31
External coatings | Russia
Andrew Chalov provides an insight
into the coating and rehabilitation
technologies in use in the demanding
Russian oil & gas pipeline sector
More than 90% of Russias 260,000km oil and gas
industry pipeline network is controlled by two compa-
nies , Gazprom and Transneft. Gazprom owns Russias
unied gas supply system - including gas extraction,
processing, transmission, storage and distribution
activities and operates some 168,000km of pipelines,
around two thirds of the total. Transnefts main activity
is in transportation of oil and petroleum products it
handles more than 90% of all the oil produced in
Russia. The company operates a total of 73,000km of
long distance pipelines, comprised of 54,000km of oil
trunk lines and 19,000km of petroleum product
pipelines. All of the other operators in Russia combined
account for just 19,000km of pipelines.
As might be expected, given the scale of their
networks, Gazprom and Transneft play key roles in
determining the factory and eld-applied coating
technologies used in Russia, which due to its extreme
climatic conditions is also a highly demanding market
for the coating industry.
The vast majority of the factory-applied coatings
used in Russia are employed for onshore pipelines. A
number of different coating systems are used, includ-
ing: fusion bonded epoxy (FBE); three layer polypropyl-
ene (3LPP); heat shrinkable tapes with hotmelt
adhesive layer (no primer); and three layer polyethylene
with primer (3LPE).
Both FBE and 3LPP coatings are sensitive to the low
temperatures experienced during Russian winters.
Some FBE coated pipe is used but it is restricted largely
to heat-insulated applications; onshore application of
3LPP in Russia is mostly in pipelines operating at high
temperatures. Heat shrinkable tapes are used in some
small production plants but this is mostly for small
diameter pipes produced at low quantities. As a
consequence, the factory-applied coating market in
Russia for onshore pipes is dominated by 3LPE.
As oil and gas extraction moves into Russias high
north and Arctic Circle regions there is a growing
demand for heat-insulated pipelines, either buried or
laid above ground (permafrost geographies frequently
make burying a pipeline impractical). Rosnefts 560km
Vankor oileld pipeline, for example, includes 200km of
above ground heat-insulated pipe (diameter 32 and
40-inch). Two heat-insulated projects are currently in
construction; Transnefts 490km Zapolarye-Purpe crude
trunkline (30% of which is buried) and Novatecs 300km
Main image:
Demand for
heat-insulated
pipelines is
growing in
Russia as
producers
move further
into the
countrys
northern
regions
External coatings for
pipelines in Russia
PIPELINE COATING | May 2014 32
Russia | External coatings
Yarudeiskoye eld gas pipeline.
For both buried and overground heat-insulat-
ed pipelines, 3LPE is the preferred coating
technology together with a factory-applied
insulation layer of PU foam. The
insulation is typically protected with an
outer layer of zinc galvanized steel
(with a 3LPE coating applied to the zinc
galvanized steel for underground
applications).
Offshore pipelines are estimated to
account for less than 1% of the total
Russian oil and gas pipeline sector. The
best known are the two 1,200km Nord Stream
pipelines under the Baltic Sea, and the 400km
section of the Blue Stream and 160km section of the
Dzhubga Lazarevskoye Sochi pipelines under the
Black Sea. 3LPP is the preferred coating solution for
offshore applications in Russia.
Field-applied coatings in use in Russia include hot
and cold applied polymer bituminous coatings (which
will be discussed later in this article), butyl rubber
tapes (no longer used by either Gazprom or Transneft
but still employed by some smaller companies), and
liquid coatings such as FBE and PU.
With 3LPE coatings dominating the Russian oil and
gas pipeline sector, it is little surprise that the main
girth weld protection option is heat-shrinkable 3LPE
sleeves. A limited, and declining, amount of mastic-
backed PE sleeving is also used, while some heat-insu-
lated pipe girth protection systems combine 3LPE with
a PU layer and coated zinc steel external protection.
The greater part of Russias oil and gas pipeline
network was constructed during the 1960s, 1970s and
1980s. It is estimated, for example, that one third of the
countrys oil trunkline network is between 20 and 30
years old, around one third older than 30 years and only
one third is younger than 20 years. In the gas sector,
Gazproms data shows just 25% of its gas trunkline (by
length) is less than 20 years old while 38% is more than
30 years old. As a result, both the major network
operators are investing considerable sums in pipeline
repair and maintenance programmes; in 2012 Gazprom
allocated RUB23.6bn (590m) in upgrading its gas
transmission network.
Gazprom will replace coatings in the eld where the
protective function has been impaired by damage but
the underlying steel is in good condition. The pipeline
will usually remain in operation during the repair
process, although operating pressures are reduced over
the repair period. A typical replacement will use a hot
applied coating process comprising: excavation of the
pipe; removal of the old coating; cleaning of the metal
surface, application of bituminous primer; application
of hot glass bre-containing mastic; application of a top
layer of crosslinked PE tape; reburial of the pipe.
Hot coating repairs can be made at a rate of between
300m and 700m per shift, depending on the pipe
diameter. It is Gazproms most commonly used in-eld
repair method but cannot be applied in all situations - it
cannot be used on pipes running at a high inclination,
for example. In such cases, slower cold applied
methods are used (cold application takes around twice
as long per linear metre).
Gazproms cold application method follows the same
process up to the point of primer application. However,
the hot applied mastic is substituted with a cold-applied
glass bre reinforced mastic tape installed by winding
with a 50% overlap and topped with a mastic-coated PE
tape.
These in-eld coating repair processes are dened
by the Gazproms VNIIGAZ technical institute and have
been in use in Russia for around a decade. It is estimat-
ed that Gazprom reinsulates around 700km of gas
pipeline each year, mostly 48 and 56-inch diameters.
Looking specically at Transnefts oil trunkline
<10 years
13.2%
<11-20 years
12.1%
<21-30 years
36.7%
<30 years
38.0%
Age of Gazprom
gas trunklines (%)
Source: Gazprom
Heat shrikable
3LPE sleeves
are the most
common girth
weld protection
option in use in
Russia
External coatings | Russia
pipeline repair processes, the company will in most
cases as much as 90% - replace damaged sections
with new pipe with a factory-applied coating. However,
it also carries out some in-eld coating repair using
both hot and cold application techniques (developed
within its own institute).
Transnefts hot applied coating process is very
similar to that used by Gazprom, differing most
signicantly in not using glass bre in the hot applied
mastic. Its cold applied method uses a different coating
system comprising a bituminous primer, glass bre-
free mastic tape, non-crosslinked polymer tape with
mastic layer, and a nal top layer of polymer tape with a
butyl rubber adhesive.
Last year, the Russian government published a
document outlining planned investments in the
countrys oil and gas transport infrastructure Territo-
rial planning scheme of the Russian Federation in the
eld of federal transportation (in terms of pipeline
transport). It includes gas, oil and petroleum product
trunklines, gas condensate pipelines, and gas distribu-
tion pipelines on Russian territory (so does not include
major cross-border projects such as South Stream).
Summing up the projects, the document shows a
potential 15,000km of new gas pipelines could come into
operation over the period from 2015 to 2030 (around
1,000km a year on average) while some 4,000km of oil
and petroleum product pipelines may begin operation
over the period to 2018 (around 800km/year).
Pipeline projects in Russia are large and there are
plenty of them. There is also growing investment in
repair and replacement of existing pipelines. As a result,
suppliers of both factory and eld-applied coatings /raw
materials, as well as girth weld protection systems, can
look forward to continuing demand for their products.
About the author:
Andrew Chalov is deputy general manager foreign trade
at Russian heat shrinkable corrosion protection
products manufacturer TIAL. His role at the company
includes market research, pricing policy development,
international certication, and export sales manage-
ment. This article is based on his own analysis of the
Russian market.
TIAL claims to be one of the largest manufac-
turers of heat shrinkable corrosion protec-
tion coatings with a production capacity of
300 tonnes a month. The companys
products carry international certication.
Aside from its domestic sales, it supplies to
a growing number of export customers.
S www.tial.ru
Russias oil and gas pipeline network extends to some 260,000km
Pipeline Coating is a new digital magazine from
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behind the hugely successful Pipeline Coating
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PIPELINE COATING | May 2014 34
conference preview | Field Joint Coating 2014
AMIs rst Field Joint
Coating conference
takes place in Germany
in September, providing
a meeting and
networking point for all
involved in the eld-
applied coating supply
chain. We take a closer
look at the event
The rst Field Joint Coating conference will be held in
Dusseldorf, Germany, on 2-4 September this year.
Organised by Applied Market Information (AMI) and
supported by Pipeline Coating magazine, this brand
new global conference focuses exclusively on eld-
applied coating solutions for steel pipelines.
Field Joint Coating 2014 is a development of AMIs
highly successful Pipeline Coating conference, which
was held for the sixth time in Vienna, Austria, in
February. The new event will be chaired by Noru Tsalic,
senior vice president at AMI Consulting, chairman and
driving force behind the Pipeline Coating conference,
and author of AMIs respected steel pipe coating market
study (Steel Pipe Coating The Global Market).
Pipelines are only as reliable as their weakest
point, says Tsalic. While line pipe is typically coated in
specialised plants under carefully controlled process
conditions, joints and rehabilitation work has to be
coated in the eld. This poses a whole array of addi-
tional challenges.
The new conference, which is sponsored by Denso,
BASF and TIAL and is booking quickly, examines all
forms of eld applied coatings, including eld joint
protection, damage repair, and in-eld coating rehabili-
tation.
Our high level speakers will provide expert insight
into coating selection and application. Which solution is
most suitable for each situation? How do they measure
up in terms of compatibility with the parent coating?
How easy are they to apply under real eld conditions?
What are the main performance and cost related
issues? All of these important questions will be
addressed, says Tsalic.
Like AMIs Pipeline Coating conference, Field Joint
Coating 2014 will also include an exhibition area (only
open to conference attendees) where delegates can
network with and learn from exhibitors in a relaxed and
informal atmosphere.
The high level conference programme covers
onshore and offshore solutions, design, testing,
certication and application of the full range of
eld-applied coatings. In this article we take a look at
the programme content and speakers.
Offshore markets
Noru Tsalic will open the conference with a review of
the global eld-applied coatings market touching on
some of the key commercial and technical areas. The
focus will then turn to offshore applications, with the
rst presentation in this session given by Bruno Cunha,
equipment engineer with Petrobras in Brazil. His paper
will look at eld joint coating solutions for use in
pre-salt areas offshore of Brazil at ultra-deep depths of
7,000m. It is a challenging environment that is expected
to account for more than half of the companys oil
production by 2018.
In-eld
application of a
tape-based
outer wrap.
Image: Denso
GmbH
Exploring FJC innovations
May 2014 | PIPELINE COATING 35
Field Joint Coating 2014 | conference preview
The development of a new solid polyurethane eld
joint coating material for application on subsea
pipelines will be explained in a joint presentation given
by Technip USA principal coatings engineer Roberto Del
Callejo Vargas and Dow Chemical Services UK offshore
coatings specialist Dave Parker. This will be followed by
discussion of a novel solution for improved offshore
pipeline eld joints given by Paul J Kleinen, vice
president engineering and technology with Bredero
Shaw in the US.
Design, testing, certication and validation are key
elements in the development of eld-applied coatings.
Dr Philippe Thibaux, technical manager at OCAS in
Belgium will present an analysis of design validation
carried out on eld-applied spacers used in a natural
gas transmission pipeline project. His presentation is
co-authored with Florenc Cochard, technical manager
at Eurpec Pipecoatings France, and Sylvain Cozzolino,
study engineer at GRTGaz in France.
Coating selection for eld joints on buried steel
pipelines will be explored by Ali Fazlinejad, general
manager of Tolerant Coating Co of Turkey, while Dr
Amal Al-Borno, president of Canadas Charter Coating
Service (2000) will explain her 3-Rs of eld joint
coating reality, repair and review.
Specication of pipeline coatings will be discussed by
Dinko Cudic, responsible for business development and
offshore engineering at Stopaq Seal for Life Industries.
His presentation will look at how design criteria can be
brought in to the specication development process. A
case study of abrasion testing on a glass bre thrust
bore coating will be presented by Tim Mally, senior
project engineer at Citadel Technologies in the US.
Coating innovations
Luc Perrad, manager of Polyguard representative
ExParTech, will speak about the advantages of selecting
non-shielding eld-applied coatings in terms of
corrosion protection. While Caio Santo Mauro and Andre
Koebsch, commercial manager and consultant
respectively at Brazil-based Polikote, will detail a new
polyurea hybrid joint coating material.
Long term performance data covering applications
for advanced three-ply tape coating systems will be
discussed by Denso Germany director of sales pipelines
international Michael Schad. And a composite pipe
repair system proven to extend pipeline lifetime by up to
20 years will be detailed by Henkel market development
manager for western Europe Bernd Hammer.
Akzo Nobel Powder Coatings global RD&I technology
manager Dr Volker Brschel will speak about the
companys latest developments in LAT eld joint powder
coatings for fast application onto temperature sensitive
steel pipe at the conference.
The discussion on coating materials will be rounded
off with a presentation on multi-component liquid
coatings for external girth weld protection by Ian
Robinson, division scientist electrical markets infra-
structure at 3M UK, while Trenton Europe sales director
Philibert de Bonnafos will speak about the use of
wax-based tapes.
Application methods
The nal session of the conference will look specically
at application of coatings in the eld. Canusa-CPS UK
EAR business development manager Peter Boyce will
open the session with a review of some of the latest
advances in eld joint coating technology. Dr Sidney A
Taylor, president of France-based Incal Pipeline
Rehabilitation, will explain the role of ow rate control
in liquid eld joint coating applications.
Matthew Green, international sales manager at NRI
in the US, will explore protection options to prevent eld
joint coating failures and pull-back during horizontal
direction drilling, while Plascoat Systems technical
business development manager Thomas Bied-Charre-
ton will explain some best practice examples for
successful application of ame sprayed coatings.
For more information:
Organised by AMI, Field Joint Coating 2014 takes place
in Dusseldorf, Germany, on 2-4 September 2014. To nd
out more about attending, exhibiting or sponsoring the
event, contact Becca Utteridge, Tel: +44 (0)117 314 8111,
Email: rju@amiplastics.com (registrations taken before
18 July 2014 qualify for a 100 booking discount).
Alternatively, visit: http://bit.ly/FJC2014
Developed
from AMIs
successful
Pipeline
Coating
conference
(pictured left),
Field Joint
Coating 2014 is
attracting
delegates from
across the
entire eld-
applied coating
supply chain
PIPELINE COATING | May 2014 36
products | Update
Osborn adds
144-knot
cut-back
brush
CLEANING
NORSOK compliant PEEK from Solvay
New option for 3LPO pipe joints
PEEK
COATINGS
POLYOLS
Industrial brush maker
Osborn has announced
availability in North America
of its 114-knot cut-back
brush for angled removal of
three or more layers of
coating from pipe ends.
The company says it
worked with leading
machine makers to develop
the new brushes, which are
heavy duty products
designed for fast and cost
effective removal of pipeline
coatings by combining pipe
edge cleaning, coating
removal and angle grinding
in one step.
The company says the
brush uses ultra-high
density AB wire and feature
a larger than normal
diameter with more knots
than competitive products
on the North American
market.
www.osborn.com
applications including but not
limited to bearings, seals,
and back-up rings.
Ketron PEEK shapes have
proven superior performance
in NORSOK M-710 sour
single-phase aging tests at
high hydrogen sulde (H
2
S)
levels. In addition, Ketron
shapes have met NORSOK
M-710 multi-phase testing
requirements.
www.solvay.com
Ultra Perform Z-2 F Poly is a
new solvent-free repair ller
from Germanys Ultra Perform
Coatings that is said to be
formulated to provide the high
levels of adhesion to PE and
PP required in pipe joint
reinstatement applications.
The new product contains a
special adhesive promoter that
allows it to bond with the
polyolen surface without the
need for pre-treatments,
according to the company. It
also incorporates a high
modulus bre reinforcement
offering temperature resist-
ance up to 250C and tear
strength of 500 N/mm
2
.
According to Ultra Perform
Coatings, which is a sister com-
pany to coatings maker
Ceramic Polymer, the Z-2 F PO
ller can provide an effective
alternative to the typical epoxy
primer and heat shrink sleeve
protection system used in
weld joint cut-back areas.
www.ultra-perform.de
Perstorp promotes
its Capa polyols
Perstorp claims that its Capa 3050 and 3091 polyols
are a good option for the formulation of high
performance protective polyurethane (PU) coatings
for pipeline products. The two Capa grades are
formulated to provide high exibility and good
chemical resistance. Both are low VOC products.
www.perstorp.com
Solvay Specialty Polymers has
announced that stock shapes
made of its KetaSpire KT-820
polyetheretherketone (PEEK)
polymer have achieved
NORSOK M-710 compliance
for use in highly demanding oil
and gas applications.
The ultra-high performance
material is one of the NORSOK
M-710 compliant resins used
by Quadrant Engineering
Plastic Products (EPP) to
produce its Ketron PEEK stock
shapes.
With down-hole operations
in the oil and gas industry
witnessing higher tempera-
tures and more severe
environmental conditions,
there is a growing trend toward
stricter requirements and the
need for even greater material
performance and durability,
says Shayel Ahmed, sales
development manager for
Spire Ultra Polymers for Solvay
Specialty Polymers.
KetaSpire PEEK delivers
good chemical and abrasion
resistance combined with
exceptional heat resistance
and strength, making it an
ideal choice in extreme oil and
gas environments. Parts
manufactured from Ketron
PEEK, based on KetaSpire
PEEK, are currently being used
in a range of oil and gas
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The latest edition of
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essential update on REACH and
the newest clarier and
nucleator products.
Click here to view
Pipeline Coating February
The February edition of Pipeline
Coating examines the latest
global energy forecasts and
reviews prospects for pipeline
investment in North America.
Plus, a look at Shells Stones
deepwater FPSO project and
details of the rst NordStream
internal inspection.
Click here to view
Injection World May
The May edition of Injection
World magazine reviews the
latest developments in the
plastic closure market. It also
looks at the latest innovations
in high temperature plastics
and new temperature control
solutions. PLUS, news from
the Chinaplas trade show.
Click here to view
ALL NEW IN THE LAST YEAR
RESISTANCE AND STABILITY OF POLYMERS CORROSION PROTECTION AGAINST HYDROGEN
PIPELINES FOR WATER
CONVEYANCE AND DRAINAGE
PIPELINE INTEGRITY HANDBOOK: RISK
MANAGEMENT AND EVALUATION
CORROSION CONTROL IN THE
OIL AND GAS INDUSTRY
2013, by Guo, Song & Ghalambor,
66.00 or 55.00 or $88.00
New edition. Revised and
expanded to include principles of
condition based maintenance.
More info/Buy here
2013, By Papavinasam,
135.00 or 110.00 or $180.00
New. Tools and methods for
corrosion management in all
industry segments.
More info/Buy here
2013, by Singh,
93.00 or 77.00 or $125.00
New. A practical day-to-day
reference ranging from risk
assessment to repair.
More info/Buy here
2013, by Beieler,
67.00 or 56.00 or $90.00
New. Manual of practice covering
11 types of pipe and 20 key
characteristics.
More info/Buy here
2014, by Schutze,
150.00 or 125.00 or $200.00
New. Essential guidance for
scientists and engineers from a
corrosion expert.
More info/Buy here
2013, by Ehrenstein & Pongratz,
500.00 or 417.00 or $667.00
1460 pages. Encompassing
chemical, mechanical, thermal and
biological effects, weathering and
radiation.
More info/Buy here N
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Visit www.pidbooks.com
for hundreds of recent titles, easy online ordering,
special offers and clearance bargains!
Order online or by telephone, fax or email. Contact Matt Wherlock,
Tel: +44 (0)117 924 9442 Fax: +44 (0)117 311 1534 email: mjw@amiplastics.com
All prices are correct at the time of publication but may be subject to change.
Please check the Plastics Information Direct website for current prices and shipping charges.
OFFSHORE PIPELINES: DESIGN, INSTALLATION,
AND MAINTENANCE, 2ND EDITION
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