OPTIMIZATION OF EXISTING GAS PIPELINES USING ADVANCED NANOCOMPOSITES
1. ●Increase Pipeline Efficiency ●Increase flow and Capacity
●Reduced Energy ●Lower GHG Emissions
In-Field FLOW Coating (IFC)
Optimization of Existing Gas Pipelines
2. • A breakthrough nanocomposite coating that
chemically bonds to the surface
+
• Insitu application using proven pig batch method
techniques
In-Field Flow Coating
3. Creating an ultra-slick, low
friction surface providing
lower friction loss,
increased flow and lower
energy consumption
In-Field Flow Coating
4. • Flow coating has a track
record of over 40 years
• Increases in capacity of 14% –
21% and higher are achievable
• Since 2016 over 70% of all
new gas pipelines
Factory Flow Coatings
5. • Applied in natural gas pipelines to smooth the
internal pipe surface for improved flow.
• A smooth surface - reduces friction and turbulence
to increase flow efficiency
• Reduction in pressure drop increases pipeline
capacity
• Reduction in fuel consumption for compression of
the gas to achieve the same flow capacity
Factory Flow Coatings
7. • Improved surface
roughness creates
laminar flow at the
internal boundary
• Laminar flow helps in
achieving the
maximum flow
capacity
8. • As pipelines age
the surface
roughness
increases
• Potential increase
in efficiency for
older pipelines is
greater
Internal Coating
9. Average Roughness Values (µinch)
Glass 50
Flow Coating 120 - 200
Commercial Steel (New) 180
Steel – Mechanically Cleaned 300-400
Steel – Chemically Cleaned 350-470
Steel – Weathered 90 Days 1000-1400
Steel – Weathered in Service > 4000
10. • The American Petroleum Institute’s API 5L2
‘Recommended Practice for Internal Coating of Line
Pipe For Non-Corrosive Gas Transmission Service’
• ISO 15741‘Paints and varnishes – Friction-reduction
coatings for the interior of on and offshore steel
pipelines for non-corrosive gases’
International Standards
11. Status and Timeline
Basic Research, Materials
Technology Development
Applied Research,
Methane emission
related
Application testing
Looking for Partners
for field trials and
demonstrations
Large Diameter
Trial
12. In-Situ Epoxy Coating Process
• 30 year old technology
• Multi step process
designed to stop
internal corrosion
• “Pig Batch” method to
clean and apply
coating
13. In-Situ Epoxy Coating Process
• 15 + mile pipeline
lengths
• 4” to 20” Diameters
• Hundreds of miles
applied
• Proven results in
multiple services
14. In-Situ Epoxy Coating Process
• Coating injected
between two pigs
• Minimum three coats
applied
• Final DFT 8-12 Mils
15. Insitu Epoxy Drawbacks
• NACE 2 “Near White”
surface prep
• HCL Acid Batches
• Water/brush pigging
• Large volumes for
larger diameters
• Long project duration
16. Insitu Epoxy Drawbacks
• Solvent based epoxies
“Pot Life” of only 3 to
5 Hours
• Not suitable for larger
diameters
• Not economical as a
flow coating
17. What is a Nano Coating?
• Nanostructures are applied to surfaces for the
purpose of sealing them on a nanoscopic scale
• Coating layer thickness in between 1-100
nanometers
• A human hair is approximately 80,000- 100,000
nanometers wide
18. What is a Nano Coating?
• Creates a self-organized, hydrophobic (water
repelling) layer of nanoscale thickness
• Does not form a layer on the substrate like
traditional coatings
• Becomes one with the substrate instead
• Creates a covalent and chemical bond
21. What is a Nanocomposite Coating?
• Formed by mixing two or more dissimilar materials at
nanoscale
• To improve the physical, chemical and
physicochemical properties
• Formulated to meet specific chemical, temperature,
abrasion and application properties
23. Pipeline Application Testing
• Application techniques and nano coating properties
were modified
• Coating pigs and speeds
• Coating viscosity
• Brush cleaned (NACE 4) and chemically cleaned
(NACE 2) surfaces results equivalent
• Reduced surface preparation time
24. Pipeline Application Testing Cont’d
• Significant reduction in surface roughness were
measured – 1 to 2 mils DFT
• Uniform coating using pig batch “Insitu” method
• Numerous brush pigs were ran on previously
coated pipe sections with no observed damage
• Not damaged by routine pigging or ILI
inspection
25. Pipeline Application Testing Cont’d
• “Pot life” very long
• Days not hours
• Application procedure is scalable for larger
diameters and long pipeline sections
• 20 + miles
• Meets API 5L2 Specifications
32. IFC Application - Existing Pipeline
• Line segment identified
• Execution Plan
development
• Line segment is de-
inventoried
• Safe for “off-line” operation
33. IFC Application - Existing Pipeline
• Temporary pig launcher
and receiver assemblies
installed
• Compressors, dryers, tanks
and pumps staged at each
end
34. IFC Application - Existing Pipeline
• Pipeline section cleaned to remove
any hydrocarbons
• Deposits and loose corrosion scale
removed – NACE 4
• Surface is treated for sulfates, sulfides
and impurities (no flash rust)
35. IFC Application - Existing Pipeline
• Line section is dried to dew point
• First coating batch is applied by “Pig
Batch” Method
• Dry air purge
• Second coating batch applied
• Final curing (drying) coating
• Line re-instatement
36. IFC Application – After Hydro Test
• Can be applied directly after hydro testing
• Surface preparation similar to drying
specification
• Use same compressors, dryers, frac tanks
already on-site
• Dry air purging after application to dew point
required
37. Benefits:
• Improves pipeline efficiency by reducing
surface friction of the pipe wall
• Increases throughput by 20% or more
• Excellent for de-rated pipelines to increase
flow capacity at decreased pressures
• Lower energy to deliver the same volume of
gas
38. Benefits cont’d:
• Lower fuel consumption results in reduced
GHG emissions
• Not damaged by routine pigging or ILI
inspection
• Suitable for all pipeline diameters
• Short “out-of-service” time
• Helps protect pipelines from internal
corrosion and black powder formation
39. 7. Midstream Company Benefit:
• 20% MORE capacity/revenue without capital infusion in
the line AND/OR the compression system
• INCREASE IN EBITA/PROFIT without increasing
CAPEX/OPEX, only cost of coating and downtime
• GREENHOUSE GAS IMPACT from lower fuel usage shown
towards corporate ESG goals
