COMPARATIVE TESTING OF 31

TANK LINING SYSTEMS

Amal Al-Borno
Charter Coating Service (2000) Ltd.
#6, 4604 – 13th Street N.E.
Calgary, AB, Canada T2E 6P1
aalborno@chartercoating.com
 PROJECT PARTICIPANTS

Amercoat Canada PPG Canada

Cloverdale Paint Petro-Canada
CNRL
RS Technologies
Corrocoat Ltd.
Sherwin-Williams
Dalco Services Inc.
Denso North America Inc. Sigma Coatings Canada
Enbridge Pipelines, Inc. SPC
Talisman
Hempel (Canada) Inc.
Tyco Adhesives
Imperial Oil Resources Limited
International Paint, Inc.
 PROJECT OBJECTIVES

● To examine and compare the performance

characteristics of tank lining systems as
selected by the study participants.

● To communicate performance data so as to

assist in the selection of appropriate coatings
for any given oil field environment.

● To encourage more interaction between

suppliers and end-users.
Coating Coating Descriptor as Used on Coating
Number Data Sheet Type % Solids
1 Epoxy Novolac Novolac 72
2 Phenolic Epoxy / Polyamino-Amide Phenolic 100
3 Epoxy /Amine and Polyamino Epoxy 100
4 Epoxy Phenolic Phenolic 64
5 Epoxy Novolac Novolac 54
6 Epoxy Novolac Novolac 72
7 Epoxy Novolac / Amine Novolac 100
8 Epoxy Epoxy 72
9 Epoxy Novolac Novolac 100
10 Vinyl Ester / Acrylic Vinyl Ester 99
11 Vinyl Ester / Urethane Vinyl Ester 99
12 Epoxy Novolac Novolac 94
13 Epoxy Epoxy 76
14 Epoxy Phenolic Phenolic 100
15 Epoxy Epoxy 95
16 Epoxy Novolac Novolac 67
17 Epoxy (Aluminum) Epoxy 60
18 Epoxy / Amine Epoxy 100
Coating Coating Descriptor as Used on Data Coating
Number Sheet Type % Solids
19 Epoxy Phenolic Novolac Novolac 73
20 Epoxy Phenolic Novolac / Amine Novolac 68
21 Phenolic Epoxy / Amine Phenolic 100
22 Novolac Novolac 100
23 Epoxy Epoxy 100
24 Phenolic Epoxy / Amine Phenolic 66
25 Vinyl Ester Vinyl Ester 98
26 Epoxy / Amine Epoxy 98
27 Epoxy Phenolic Novolac Novolac 70
28 Epoxy Phenolic Novolac / Amine Novolac 80
29 Epoxy Novolac Novolac 90
30 Epoxy Novolac (Siliconized) Novolac 97
31 Phenolic Epoxy / Amine Phenolic 100
 COATING TYPES

Vinyl Ester
(3 coatings)
10%

Epoxy
Phenolic (8 coatings)
(6 coatings) 26%
19%

Novolac
(14 coatings)
45%
 APPLICATION AND SAMPLE CUTTING
● All coatings were applied by the same applicator
according to suppliers’ recommended
procedures and under suppliers’ direction.

● Cured samples were cut using a water-jet cutting

system.
 TESTS at 60˚C/140˚F
Test Conditions (ALL 28 Day Tests)

Soak Adhesion Water: 1% NaCl in distilled water

CSA Z245.20
Cathodic Disbondment Solution: 3% NaCl in distilled water
CSA Z245.20 Voltage: -1.5V
Atlas Cell Test Thermal Gradient: 25˚C
NACE TM 0174 Air; 1% NaCl aq.; 1:1 toluene: kerosene
Pressurized Atlas Cell Pressure: 1.4MPa/200 psi
(PAC) Gas: 5% H2S, 5% CO2, 90% CH4
NACE TM 0174 1% NaCl aq.; 1:1 toluene: kerosene
Electrochemical 1) Untested samples
Impedance Spectroscopy 2) Water phase of PAC samples after 28
(EIS) Days
 HIGHER TEMPERATURE TESTS

Test Conditions
Atlas Cell Test Temp.: 85˚C/185˚F, Thermal Gradient: 25˚C
NACE TM 0174 Air; 1% NaCl aq.; 1:1 toluene:kerosene; 28 days
Pressurized Atlas Cell Temp.: 100˚C/212˚F, Pres.: 1.4MPa/200 psi
NACE TM 0174 Gas: 5% H2S, 5% CO2, 90% CH4
1% NaCl aq.; 1:1 toluene: kerosene; 28 days
Temp.: 100˚C/212˚F, Pres.: 6.89MPa/1000 psi
Gas: 5% H2S, 5% CO2, 90% CH4
Autoclave Tests 1% NaCl aq.; 1:1 toluene: kerosene; 168 hours
NACE TM 0185 Test conditions as above but including mid-cycle
rapid depressurization
Temp.: 125˚C/257˚F; Pres.: 0.34 MPa/50 psi
Vapor; 1% NaCl aq.; 1:1 toluene: kerosene; 168
hours
ACCELERATING COMPONENTS IN TEST
CONDITIONS
● Low 1 % NaCl concentration in most tests (more
aggressive than 3% solutions).
● High thermal gradient (25ºC) for standard atlas
cell test.
● H2S and CO2 used in pressurized atlas cell and
100 ºC autoclave test.
● Rapid depressurization used for one of the
autoclave tests.
● High temperatures.
 “GOOD PERFORMANCE” CRITERIA
● Soak Adhesion Test: CSA FBE coatings’ test
modified. Pass/fail 1-3 (pass = “good”).
● Cathodic Disbondment Test: CSA FBE coatings’
test modified. One variable, the disbondment radius.
Performance based on comparison with similar
coatings and other coatings in this study. “Good” =
less than 15 mm.
● Atlas Cell and Autoclave Tests: No single
characteristic that can be analyzed. In this study
“good performance” is defined as being:
● does not blister or crack in any phase
● maintains an adhesion of ‘C-’ or better
 SOAK ADHESION
(CSA Z245.20-02)

● Water can be an aggressive environment to a coating

system, especially at elevated temperatures.

● The hot water soak test examines a coating’s ability to

remain well adhered to the steel in immersion conditions.

Conditions:
Temperature: 60°C/140°F
Water: 1% NaCl Solution
Duration: 28 days
 SOAK ADHESION TEST

3 3

Pre-Test Data
Adhesion Rating

Post-Test Data
2 2
Adhesion Rating

1 1

0 0
1 12 23 3 4 45 5 6 6 7 7 8 8 9 910 1011 1112 1213 1314 1415 15161617 1718 18191920 2021 2122 22232324 2425 2526 262727282829 2930 3031 31
Coating
CoatingNumber
Number
*Decimal value denot es t he average of t wo disparat e pre-t est scores.
Rating 4 Rating 2 Rating 1
 CATHODIC DISBONDMENT
(CSA Z245.20-M92)

 This test measures the resistance of a coating to

disbondment under conditions that simulate cathodic
protection.
 Typically the bottom of the tank is the area most prone to
effect from cathodic protection owing to the placement of
anodes in the tank.

Conditions:
Temperature: 60˚C/140˚F
Solution: 3% NaCl Solution
Voltage: -1.5V
Duration: 28 days
 Disbondment Radius (mm)

0
15
40

5
10
20
25
30
35
9
12 Excellent
22
7
23
10

Very
Good
11
25
17
2
1
Good

4
20
31
18 Moderate
21
19
30
Coating Number 13
29
3
6
14
15
Poor

26
8
5
27
16
CATHODIC DISBONDMENT BY COATING

28
24
 CATHODIC DISBONDMENT AT 60˚C BY
COATING TYPE
100%
100%

90%
90% < 15 mm
15 - 20 mm
Coatings

80%
80%
> 20 mm
70%
70%
Coatings

5 8
60%
60%
Percentage of of

3 3
50%
6
Percentage

50%

40%
40% 2
30%
2
30%
1
20%
20%
1
10%
10%

0%
0%

Epoxy
Epoxy (8)
(8) Novolac
Novolac (14)
(14) Phenolic (6)
Phenolic (6) Vinyl
VinylEster (3)
Ester (3)

Coating Type (Number of Coatings)

Coating Type (Number of Coatings)
 STANDARD ATLAS CELL
(Modified NACE TM0174-91)
● The ability of the coating to withstand immersion conditions
under the stress of a thermal gradient.

● This test simulates the cold wall affects in non-insulated

tanks and vessels.

Conditions:
Internal Temperature: 1st test 60°C/140°F
2nd test 85°C/185°F
Thermal Gradient: 25˚C/70˚F
Gas: Air
Water: 1% NaCl Solution
Hydrocarbon: 1:1 Toluene: Kerosene
Duration: 28 Days
 controller
thermocouples

cooling
jacket

sample panels heating jacket

 PRESSURIZED ATLAS CELL
(Modified NACE TM0174-91)
● This test examines the resistance of coatings to the
combined affects of temperature, pressure, cold wall, and
chemical environment.
● Determines performance in conditions that simulate
pressurized vessels in sour service.

Conditions:
Internal Temperature: 1st test 60°C/140°F
2nd test 100°C/202°F
Pressure: 1.4MPa/200 psi
Gas: 5% H2S, 5% CO2, 90% CH4
Water: 1% NaCl Solution
Hydrocarbon: 1:1 Toluene : Kerosene
Duration: 28 Days
heating jackets controllers pressure gauges

samples (hidden)
 ATLAS CELLS AND CATHODIC DISBONDMENT DATA
Standard Atlas Cell 10/31 Pressurized Atlas Cell 16/31 Cathodic
Coating Disbondment
Number Gas Hydrocarbon Water Gas Hydrocarbon Water
Phase Phase Phase Phase Phase Phase Performance
Phenolic 2 C_ C_ C_ C_ C_ C_ good
Novolac 5 -- -- -- B A B- poor
Novolac 6 -- -- -- C B C poor
Novolac 7 C_ C_ C_ C C C very good
Standard Atlas Cell Pressurized Atlas Cell
Epoxy 8 B A C B A C poor
Gas Phase
Novolac 9 -- -- -- Gas
C Phase C C excellent
Vinyl Ester 10 C C C B B B_ very good
Vinyl Ester 11 C C C C C C very good
Novolac 12 C C C_ C C C excellent
Hydrocarbon Phase
Hydrocarbon
Novolac 16 Phase A A B A A A poor
Epoxy 18 A A C A A B+ moderate
Novolac 22 -- -- -- A A A excellent
Phenolic 24 A A A A A A poor
Water
Vinyl Ester 25PhaseB B C BWater Phase
B B very good
Novolac 27 -- -- -- A A A poor
Novolac 28 -- -- -- A A A poor
 STANDARD AND PRESSURIZED ATLAS
CELL AT 60˚C BY COATING TYPE
Standard Pressurized
Atlas Cell Atlas Cell
10 / 31 Good 16 / 31 Good

100%
Percentage of Coatings with

90%
“Good Performance”

80%

70% 3 3
60%
50%
9 2 2
40%
30% 2 2 3
20%
10%
0%
Epoxy (8) Novolac (14) Phenolic (6) Vinyl Ester (3)

Coating Type (Number of Coatings)

 ELECTROCHEMICAL IMPEDANCE
SPECTOSCOPY (EIS)
● Used to evaluate the integrity of coatings, their barrier
properties, and predict their corrosion protection
characteristics.
● Conducted using conditions as in other immersion
tests (1% NaCl aq., 60˚C/140˚F, 28 days)
● untested coatings

● PAC (water phase)

 EIS DATA

EIS Data @ 60ºC/140ºF

10
Untested Coating After 28 Days at 60ºC in Pressurized Atlas Cell

9 B B B

B
8
B

6
B
Log Z at 0.1 Hz

5 B B
B B
B B B B
4 B
B

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B - Bisters after PAC Testing Coating Number
B - Bisters after EIS Testing
 EIS DATA AFTER PRESSURIZED ATLAS
CELL TEST BY COATING TYPE
10 ? ? ?
9
Log Z at 0.1 Hz

8
7
6
?
?
5 ?
4
3
2
1
0
Epoxy Novolac Phenolic Vinyl
Ester
Coating Type

Some coatings that were failing looked good on EIS and some coatings
that looked poor in EIS performed well as corrosion barriers. Shows
limitations of EIS as an indicator of coating performance/degradation.
 EIS DATA OF UNTESTED COATINGS
COMPARED TO CATHODIC
DISBONDMENT RADIUS
10.0
10

9.0
9
Hz Hz

8
8.0
0.1
at 0.1

7
7.0
Z Zat

5 worst coatings in EIS

LogLog

6
6.0

5
5.0

4
4.0
0
0 55 10
10 15
15 20
20 25
25 30
30 35
35 40
40
Disbondment Radius (mm)
Disbondment Radius (mm)
SOME GOOD COATINGS IN 60˚C/140˚F TESTS
Coating # Soak Atlas Cell PAC CD
Phenolic 2 3-4 Good Good Good 11 mm
Novolac 7 2 Good Good V. Good 10 mm
Epoxy 8 1 Good Good Poor 28 mm
Novolac 9 2 Poor Good < 10 mm
Vinyl Ester 10 2 Good Good V. Good 10 mm
Vinyl Ester 11 2 Good Good V. Good 10 mm
Novolac 12 2 Good Good < 10 mm
Novolac 16 1 Good Good Poor 35 mm
Epoxy 18 1 Good Good Moderate 16mm
Novolac 22 1 Poor in Water Good < 10 mm
Phenolic 24 2 Good Good Poor 36 mm
Vinyl Ester 25 2 Good Good V. Good 10 mm
 SELECTION OF COATINGS FOR HIGHER
TEMPERATURE TESTING

● Coatings not recommended for high temperatures were not

tested above 60˚C/140˚F.
● Coatings that were to be tested at a different film thickness
were included in all the higher temperature tests.
● Coatings that did not have good performance in the
60˚C/140˚F Standard Atlas Cell test were not tested in the
85˚C/185˚F test.
● Coatings that did not have good performance in the
60˚C/140˚F Pressurized Atlas Cell test were not tested in
the 100˚C/212˚F test.
 AUTOCLAVE (Optional)
(Modified NACE TM0185-93)
Determines performance under conditions that simulate the
environment in an insulated vessel.

Conditions:
Temperature: 1st test 100°C/202°F
2nd test 125°C/257°F
Pressure: 1st test 6.89MPa/1000 psi
2nd test 0.34 MPa/50 psi
Gas: 1st test 5% H2S, 5% CO2, 90% CH4
2nd test Vapor
Water: 1% NaCl Solution
Hydrocarbon: 1:1 Toluene : Kerosene
Duration: 168 hours
Mid-Cycle Rapid Depressurization included
for duplicate of 1st set of test conditions
 COATINGS WITH GOOD PERFORMANCE AT
HIGH TEMPERATURE BY COATING TYPE

Standard Atlas Cell (85 C)

Pressurized Atlas Cell (100 C)
Percentage with “Good Performance”

100%
100%
90%
90% Autoclave (100C)
Percentage with "Good Performance"

Autoclave with Rapid Depress. (100 C)

80%
80%

70%
70%

4 3
60%
60% 9
50%
50%
(20) 1
40%
40%
2 (24) (2)
30%
30% (28)
1 1
20%
20% 2 2
1
10%
10%
0 0 0 0 0 0
0%
0%
Epoxy
Epo xy (8)(8) Novolac (14)
No vo lac (14) Phenolic
P henolic (6) (6) Vinyl
VinylEster
Ester (3) (3)

CoatingCoating
Type (Number of Coatings)
Type (Number of Coatings)

Autoclave with Mid-Cycle Rapid Depressurization

Standard Atlas Cell Pressurized Atlas Cell

Autoclave with NO Mid-Cycle Rapid Depressurization

Autoclave with Mid-Cycle Rapid Depressurization

Autoclavewith
Autoclave withMid-Cycle
Mid-CycleRapid
RapidDepressurization
Depressurization
 CONCLUSIONS FOR HIGH
TEMPERATURE TESTS
● Fewer coatings perform well, more care required in selection
● All 25 tested coatings performed well at 125C/257F in water
and hydrocarbons, but other factors (see below) tended to
result in coating degradation.
● Especially susceptible to thermal gradient with only one good
performance (Number 24, a Phenolic) in 85˚C/185˚F Standard
Atlas Cell.
● In the presence of acid gases and a pressure of 6.89
MPa/1000 psi 19 of 25 tested coatings performed well.
● Coatings tended to blister and/or suffer severe adhesion loss
when subjected to rapid depressurization. Only Numbers 2,
20 and 28 didn’t. However some coatings formed small
surface blisters, some of which recovered after test, indicating
resistance to degradation.
 SUMMARY OF COATINGS WITH “Good
Performance” (not marked = Not Tested/Not Good)
Standard Pressurized Standard Pressurized Autoclave
Coating CD Test Autoclave Autoclave
Atlas Cell Atlas Cell Atlas Cell Atlas Cell 100ºC/212ºF
Number 60ºC/140ºF 100ºC/212ºF 125ºC/257ºF
60ºC/140ºF 60ºC/140ºF 85ºC/185ºF 100ºC/212ºF Blow-Down

Novolac 1 Good Good

Phenolic 2 Good Good Good Good Good Good
Epoxy 3
Phenolic 4 Good Good
Novolac 5 Good Good
Novolac 6 Good Good Good Good
Novolac 7 Very Good Good Good Good Good
Epoxy 8 Good Good Good Good
Novolac 9 Excellent Good Good
Vinyl Ester 10 Very Good Good Good Good Good
Vinyl Ester 11 Very Good Good Good Good Good Good
Novolac 12 Excellent Good Good Good Good
Epoxy 13 Good Good
Phenolic 14
Epoxy 15
Novolac 16 Good Good Good Good Good
 SUMMARY OF COATINGS WITH “Good
Performance” (not marked = Not Tested/Not Good)
Standard Pressurized Standard Pressurized Autoclave
Coating CD Test Autoclave Autoclave
Atlas Cell Atlas Cell Atlas Cell Atlas Cell 100ºC/212ºF
Number 60ºC/140ºF 100ºC/212ºF 125ºC/257ºF
60ºC/140ºF 60ºC/140ºF 85ºC/185ºF 100ºC/212ºF Blow-Down

Epoxy 17 Good
Epoxy 18 Moderate Good Good Good Good
Novolac 19
Novolac 20 Good Good Good Good
Phenolic 21 Moderate Good Good
Novolac 22 Excellent Good Good Good
Epoxy 23 Very Good Good
Phenolic 24 Good Good Good Good Good
Vinyl Ester 25 Very Good Good Good Good Good
Epoxy 26 Good
Novolac 27 Good Good Good
Novolac 28 Good Good Good Good
Novolac 29 Good Good
Novolac 30 Good Good
Phenolic 31 Good Good Good
 SUMMARY CONCLUSIONS
● Most problems seen in the water phase.
● Higher Temperature or higher Thermal Gradient
are most likely to result in coating degradation.
● Many coatings disbond in the presence of an
impressed cathodic potential at 60˚C/140˚F .
● Emergency Depressurization tends to cause
blistering/loss of adhesion.
● Lots of variation within a given Coating Type
(resin type) – don’t buy generics!
● Need to test selected coatings in environments
that simulate actual service environment.
COMPARATIVE TESTING OF 31
TANK LINING SYSTEMS

Amal Al-Borno
Charter Coating Service (2000) Ltd.
#6, 4604 – 13th Street N.E.
Calgary, AB, Canada T2E 6P1
aalborno@chartercoating.com