What is the difference between external pipe coating and internal pipe lining and cladding? External pipe coatings are used to protect the metal from corrosive environments (3LPE-coated pipes are the most common choice). Internal lining (for example PTFE) protects the pipe from corrosive fluids. Clad pipes (CRA or “Bimetallic Pipes”) have the inner surface covered by higher-grade materials to achieve stronger resistance while decreasing the overall pipe cost.
EXTERNALLY COATED PIPES
Coated pipes, also known as pipe coatings, refer to steel pipes that have been treated with protective coatings to enhance their corrosion resistance, durability, and performance in various environmental and operating conditions.
These coatings are applied to the external and/or internal surfaces of pipes to provide protection against corrosion, abrasion, chemical attack, and other forms of degradation.
Coated pipes are commonly used in industries such as oil and gas, water distribution, construction, and infrastructure development. Here are some common types of coatings used for pipes:
Typical Coating Materials
Fusion-Bonded Epoxy (FBE)
FBE coatings are thermosetting epoxy powders applied to the external surface of pipes using electrostatic spray or fluidized bed deposition methods. Once applied, the coating is cured to form a tough, protective layer that resists corrosion and mechanical damage.
Three-layer polyethylene (3LPE)
3LPE coatings consist of a fusion-bonded epoxy primer, an adhesive layer, and a polyethylene topcoat. These coatings provide excellent resistance to corrosion, moisture, and mechanical stress, making them suitable for underground and underwater applications.
3LPE-coated pipes feature a three-layer polyethylene coating consisting of:
- a high-performance fusion bonded epoxy (FBE),
- a copolymer adhesive
- an outer layer of polyethylene which provides tough, durable protection against corrosion and erosion.
3LPE pipe suit medium to high operating temperatures.
(Source: Wasco Energy Youtube Channel)
Three-layer polypropylene (3LPP)
Similar to 3LPE coatings, 3LPP coatings consist of an epoxy primer, an adhesive layer, and a polypropylene topcoat. These coatings offer superior chemical resistance and higher operating temperatures compared to polyethylene coatings.
Coal Tar Enamel (CTE)
CTE coatings are solvent-based bituminous coatings applied to steel pipes by hot-dipping or wrapping methods. While less common than epoxy or polyethylene coatings, CTE coatings provide effective corrosion protection and can withstand high temperatures and abrasive conditions.
Polyurethane (PU)
PU coatings are solvent-based or powder coatings applied to pipes to provide abrasion resistance, chemical resistance, and UV stability. These coatings are often used in offshore and marine environments where high-performance coatings are required.
Other non-metallic pipe coatings
Paints, varnishes, lacquers, bituminous coatings, resins, plasticizers, Greases, waxes, oils, other plastics (Rilsan, PTFE, PVC), Elastomers (various types), Vitreous enamel, Cement mortar
Organometallic pipe coating
Paints pigmented with metals in powder form (aluminum, zinc, lead, stainless steel), Paints containing zinc ethyl-silicate
Chemical modification
Phosphating, Chromatin, phosphating, Black finishing, and browning
Cementation
Application of an external layer of cement to achieve physiochemical modification
Advantages/Disadvantages of Pipe Coating Materials
The main types of non-metallic pipe coating materials, and their advantages/disadvantages, are summarized in the table below:
Pipe Coating Type | Advantages | Disadvantages |
Three-layer Polyethylene (3LPE) and 3 layers of Polypropylene (3LPP) | Low material and application cost |
|
Polypropylene (PUR) | Recommended for deep sea applications with relatively high temperatures and pressures | Polypropylene is liable to chain degradation from exposure to heat and UV radiation such as that present in sunlight. |
Fusion Bonded Epoxy (FBE) | Excellent chemical resistance and great dimensional stability with minimized hysteresis |
|
Asphalt enameled and polyurethane (PUR) | Cheap and superior to coal enamel reduces hysteresis Fast treatment |
|
External Pipe Coating: Benefits
Coated pipes offer several benefits, including:
- Corrosion Protection: Coatings provide a barrier against corrosive substances, preventing the steel substrate from coming into contact with moisture, chemicals, and other corrosive agents.
- Extended Service Life: Coated pipes are more durable and have a longer service life compared to uncoated pipes, reducing maintenance costs and downtime.
- Improved Flow Efficiency: Internal coatings reduce friction and resistance, improving flow efficiency and reducing energy consumption in fluid transport systems.
- Environmental Protection: Coatings help to prevent leaks, spills, and environmental contamination by maintaining the integrity of pipelines and preventing corrosion-related failures.
Overall, coated pipes are essential components in various industries where corrosion protection, durability, and performance are critical requirements for infrastructure and asset integrity.
INTERNALLY LINED PIPES
Lined pipes, also known as pipe liners, refer to steel pipes that have been internally lined with a protective layer or lining material to enhance their corrosion resistance, chemical resistance, and abrasion resistance. These linings are applied to the internal surface of pipes to protect the steel substrate from the effects of corrosive fluids, abrasive materials, and other harsh operating conditions. Lined pipes find applications in industries such as oil and gas, chemical processing, water treatment, and power generation.
Lined pipes are fitted with an internal protective material which is mechanically inserted into the tubular section. The lining material is fitted into the pipe at the end of the manufacturing process. It is clear that internal lining materials, which have their own thickness, reduce the bore size of the pipe.
Pipe Internal Lining Materials
Here are some common types of linings used for pipes:
1. Rubber Lining
- Rubber linings, typically made of natural or synthetic rubber compounds, are applied to the internal surface of pipes using vulcanization or bonding techniques.
- Rubber linings offer excellent resistance to corrosion, abrasion, and chemical attack, making them suitable for handling corrosive fluids, slurries, and abrasive materials.
- Rubber-lined pipes are commonly used in industries such as mining, mineral processing, and chemical processing, where aggressive environments are present.
2. Polymer Lining
- Polymer linings, such as polyethylene (PE) or polypropylene (PP), are applied to the internal surface of pipes using fusion-bonded or adhesive bonding methods.
- Polymer linings provide superior resistance to corrosion, chemical attack, and high temperatures, making them suitable for a wide range of applications in corrosive environments.
- Polymer-lined pipes are used in industries such as water and wastewater treatment, chemical processing, and semiconductor manufacturing, where chemical resistance and purity are essential.
3. Ceramic Lining
- Ceramic linings, composed of alumina, zirconia, silicon carbide, or other ceramic materials, are applied to the internal surface of pipes using adhesive bonding or thermal spray methods.
- Ceramic linings offer exceptional resistance to abrasion, erosion, and high temperatures, making them suitable for handling abrasive slurries and high-velocity flows.
- Ceramic-lined pipes are commonly used in industries such as mining, power generation, and pulp and paper processing, where severe abrasion and wear are encountered.
4. Glass Lining
- Glass linings, also known as vitreous enamel linings, are applied to the internal surface of pipes using a fritting process or glass-fused-to-steel technology.
- Glass linings provide excellent resistance to corrosion, abrasion, and chemical attack, as well as high temperatures and thermal shock.
- Glass-lined pipes are used in industries such as pharmaceuticals, food and beverage processing, and specialty chemicals, where cleanliness, purity, and corrosion resistance are critical requirements.
5. Other lining materials
- Teflon (PTFE)
- Cement mortar
- Liquid epoxy
- Fusion bonded epoxy (FBE)
- Bituminous asphalt
- Zinc
Internal Pipe Lining: Benefits
Lined pipes offer several benefits, including:
- Corrosion Protection: Linings provide a protective barrier against corrosive fluids, preventing the steel substrate from coming into contact with corrosive agents.
- Abrasion Resistance: Linings offer resistance to abrasive materials and erosive flows, extending the service life of pipes in high-wear applications.
- Chemical Resistance: Linings resist chemical attacks from acids, alkalis, and other corrosive substances, ensuring the integrity of pipelines in aggressive environments.
- Smooth Flow Characteristics: Some linings improve flow efficiency by reducing friction and resistance, minimizing pressure drop and energy consumption in fluid transport systems.
Overall, lined pipes are essential components in industries where corrosion protection, abrasion resistance, and chemical resistance are critical requirements for maintaining infrastructure integrity and operational reliability.
CLAD PIPES (CRA or Bimetallic Pipes)
Clad pipes, also known as bimetallic pipes or clad-lined pipes, are composite pipes that consist of a steel core or base material clad with a corrosion-resistant alloy layer on the external or internal surface.
Clad pipes are also called CRA (which stands for “corrosion-resistant alloy”).
These pipes combine the mechanical strength of steel with the corrosion resistance of alloy materials, offering enhanced performance and durability in corrosive environments.
Clad pipes are commonly used in industries such as oil and gas, chemical processing, and water treatment, where corrosion resistance and reliability are critical requirements.
Key Features of Clad Pipes
Here are some key features and types of clad pipes:
1. Structure and Construction
- Clad pipes typically consist of a steel core or base material, such as carbon steel or low-alloy steel, with a corrosion-resistant alloy layer bonded to one or both surfaces.
- The alloy layer is applied to the base material through various bonding methods, such as explosion bonding, roll bonding, diffusion bonding, or weld overlay techniques.
- The alloy layer may cover the entire surface area of the pipe (full clad) or only specific regions exposed to corrosive environments (partial clad).
2. Types of Cladding Materials
- Corrosion-Resistant Alloys: Cladding materials commonly used for corrosion resistance include stainless steels (e.g., 316L, 317L), nickel alloys (e.g., Alloy 625, Alloy 825), and duplex stainless steels (e.g., UNS S31803, UNS S32205).
- Wear-Resistant Alloys: In addition to corrosion resistance, clad pipes may incorporate wear-resistant alloys such as hard-facing materials (e.g., tungsten carbide) to improve resistance to abrasion and erosion in high-wear applications.
- High-Temperature Alloys: Cladding materials may also include high-temperature alloys (e.g., Alloy 800H, Alloy 625) for applications involving elevated temperatures and thermal cycling.
3. Applications and Benefits
- Corrosion Resistance: Clad pipes offer superior resistance to corrosion, pitting, crevice corrosion, and stress corrosion cracking compared to conventional steel pipes, extending service life in aggressive environments.
- Cost-Effectiveness: Clad pipes provide a cost-effective solution for achieving corrosion resistance in corrosive environments without the need for expensive solid alloy materials.
- Flexibility and Versatility: Clad pipes can be tailored to specific application requirements by selecting appropriate cladding materials and thicknesses, offering flexibility in design and performance optimization.
- Enhanced Performance: Clad pipes combine the mechanical properties of steel with the corrosion resistance of alloy materials, providing enhanced performance and reliability in demanding operating conditions.
- Reduced Maintenance: Clad pipes require less maintenance and downtime compared to solid alloy pipes, resulting in cost savings and improved operational efficiency over the lifecycle of the pipeline.
4. Applications
- Clad pipes are widely used in various industries and applications, including offshore oil and gas production, chemical processing plants, refineries, desalination plants, and power generation facilities.
- They are employed in applications such as subsea pipelines, process piping, heat exchanger tubing, reactor vessels, and sour service environments where corrosion resistance and reliability are critical requirements.
A clad pipe combines the strength and toughness of a carbon steel pipe with the corrosion resistance of a stainless or duplex pipe (or even higher grades, such as nickel high-alloyed materials like Inconel, Incoloy, etc).
SUPPLIERS OF PIPE COATING/LINING/CLADDING SERVICES
PIPE COATING SUPPLIERS
Several companies specialize in providing pipe coating services for various industries, including oil and gas, water distribution, infrastructure, and construction.
These companies offer a wide range of coating solutions to protect steel pipes from corrosion, abrasion, and other forms of degradation. Here are some suppliers of pipe coating services:
- Shawcor Ltd.: Shawcor is a global leader in providing pipeline coating and corrosion protection services. They offer a comprehensive range of coating solutions, including fusion-bonded epoxy (FBE), three-layer polyethylene (3LPE), three-layer polypropylene (3LPP), and concrete weight coating (CWC) for onshore and offshore pipelines.
- Bredero Shaw: Bredero Shaw, a division of Shawcor Ltd., specializes in providing pipeline coating services for the oil and gas industry. They offer a wide range of coating technologies, including FBE, 3LPE, 3LPP, and internal flow efficiency coatings, as well as custom coating solutions tailored to specific project requirements.
- Consolidated Pipe & Supply Company: Consolidated Pipe & Supply Company offers pipe coating services, including FBE, 3LPE, and internal coatings, at their state-of-the-art coating facilities. They provide coating solutions for a wide range of pipe sizes and applications, including water transmission, wastewater treatment, and industrial pipelines.
- Bayou Companies: Bayou Companies, a subsidiary of Primoris Services Corporation, provides pipe coating and lining services for the oil and gas industry. They offer FBE, 3LPE, 3LPP, and internal coatings, as well as custom coating solutions for pipelines, risers, and subsea infrastructure.
- Tnemec Company, Inc.: Tnemec Company, Inc. specializes in providing high-performance coatings for steel pipes and structures in various industries. They offer a wide range of protective coatings, including epoxy, polyurethane, and fluoropolymer coatings, designed to withstand harsh environmental conditions and chemical exposure.
- Blastech Rail Services Inc.: Blastech Rail Services Inc. provides pipe coating services for the transportation, infrastructure, and industrial sectors. They offer FBE, 3LPE, and 3LPP coatings, as well as custom coating solutions for pipelines, structural steel, and railcar components.
- Axalta Coating Systems: Axalta Coating Systems offers a range of corrosion protection coatings for steel pipes and structures. They provide epoxy, polyurethane, and thermoplastic coatings designed to withstand corrosive environments and provide long-lasting protection.
- Denso North America Inc.: Denso North America Inc. specializes in providing corrosion prevention and sealing systems for pipelines and infrastructure. They offer a variety of protective coatings, including petrolatum tapes, wax tapes, and heat-shrink sleeves, designed to protect steel pipes from corrosion and mechanical damage.
- Vestas Industrial Coating Solutions: Vestas Industrial Coating Solutions provides pipe coating services for the oil and gas, water, and wastewater industries. They offer FBE, 3LPE, and internal coatings, as well as custom coating solutions for pipelines, tanks, and vessels.
- International Paint: International Paint, a subsidiary of AkzoNobel, offers a range of protective coatings for steel pipes and structures. They provide epoxy, polyurethane, and zinc-rich coatings, as well as specialty coatings for offshore and marine applications.
These are just a few examples of companies that offer pipe coating services. It’s essential to choose a reputable and experienced supplier that can provide high-quality coatings tailored to your project requirements and environmental conditions.
PIPE LINING SUPPLIERS
Several companies specialize in providing pipe lining services to protect steel pipes and enhance their performance in various industries. These companies offer a range of lining solutions to prevent corrosion, abrasion, and other forms of degradation. Here are some suppliers of pipe lining services:
- U.S. Pipe: U.S. Pipe offers pipe lining services for water and wastewater applications. They provide cement mortar lining (CML) and polyurethane lining services for steel pipes to protect against corrosion and improve flow efficiency.
- T. D. Williamson: T. D. Williamson (TDW) specializes in providing pipeline maintenance and rehabilitation solutions. They offer lining and coating services for pipelines, including cement mortar lining (CML), epoxy lining, and polyurethane lining, to protect against corrosion and extend the service life of pipelines.
- Sauereisen: Sauereisen provides corrosion-resistant lining systems for steel and concrete substrates in various industries. They offer epoxy and vinyl ester lining systems designed to protect against chemical attack and abrasion in harsh environments.
- Pipeline Linings Pty Ltd: Pipeline Linings Pty Ltd offers pipeline lining and rehabilitation services for water, wastewater, and industrial pipelines. They provide cement mortar lining (CML), epoxy lining, and polyurethane lining services to protect against corrosion and improve flow characteristics.
- Reline Group: Reline Group specializes in trenchless pipe rehabilitation solutions, including pipe lining and relining services. They offer cured-in-place pipe (CIPP) lining, spray lining, and epoxy lining services for sewer, stormwater, and pressure pipelines.
- AP/M Permaform: AP/M Permaform offers trenchless pipe rehabilitation solutions for municipal and industrial applications. They provide spiral-wound pipe lining systems, including PVC, HDPE, and fiberglass liners, to repair and rehabilitate deteriorated pipelines.
- National Linings Systems: National Linings Systems provides corrosion protection and containment lining solutions for steel and concrete structures. They offer epoxy, polyurethane, and hybrid lining systems for tanks, pipes, and secondary containment areas.
- Inliner Technologies: Inliner Technologies specializes in CIPP (cured-in-place pipe) lining solutions for sewer and stormwater pipelines. They offer trenchless rehabilitation services using resin-impregnated liners to restore the structural integrity and flow capacity of pipelines.
- PICA Corporation: PICA Corporation offers pipeline inspection, assessment, and rehabilitation services for water, wastewater, and oil and gas pipelines. They provide robotic pipe lining solutions, including cement mortar lining (CML) and epoxy lining, to rehabilitate deteriorated pipelines.
- Interplastic Corporation: Interplastic Corporation offers corrosion-resistant lining systems for industrial applications. They provide vinyl ester, epoxy, and polyester lining systems to protect steel and concrete substrates from chemical attack and abrasion.
These are just a few examples of companies that offer pipe lining services. It’s essential to choose a reputable and experienced supplier that can provide high-quality lining solutions tailored to your project requirements and environmental conditions.
PIPE CLADDING SUPPLIERS
Pipe cladding services involve applying a layer of corrosion-resistant alloy onto the external or internal surface of steel pipes to enhance their durability and performance in corrosive environments. Several companies specialize in providing pipe cladding services for various industries, including oil and gas, chemical processing, and power generation.
Here are some suppliers of pipe cladding services:
- Bodycote Surface Technology: Bodycote Surface Technology offers a range of surface engineering solutions, including pipe cladding services. They provide thermal spray coatings, such as metal alloy coatings and ceramic coatings, to protect steel pipes from corrosion, wear, and erosion.
- Hertel GmbH: Hertel GmbH specializes in providing industrial services, including pipe cladding and welding solutions. They offer overlay welding services using corrosion-resistant alloys to protect steel pipes from corrosion and extend their service life in aggressive environments.
- Stork Technical Services: Stork Technical Services provides integrated maintenance and integrity solutions for industrial assets, including pipe cladding services. They offer weld overlay cladding using nickel alloys, stainless steel, and other corrosion-resistant alloys to protect pipelines and process equipment.
- Vallourec: Vallourec is a leading supplier of tubular solutions for the oil and gas industry. They offer pipe cladding services using metallurgical bonding techniques, such as explosion bonding and roll bonding, to apply corrosion-resistant alloy layers onto steel pipes for offshore and onshore applications.
- SANDVIK Group: SANDVIK Group offers a wide range of materials and services for various industries, including pipe cladding solutions. They provide weld overlay cladding using advanced welding technologies and corrosion-resistant alloys to protect pipelines and components from corrosion and wear.
- GAS Arabian Services: GAS Arabian Services specializes in providing engineering and construction services for the oil and gas industry. They offer pipe cladding services using overlay welding techniques to apply corrosion-resistant alloys onto steel pipes for upstream and downstream applications.
- Cor-Pro Systems, Inc.: Cor-Pro Systems, Inc. provides corrosion protection solutions for industrial assets, including pipe cladding services. They offer thermal spray coatings, weld overlay cladding, and corrosion inhibitors to protect steel pipes from corrosion, erosion, and chemical attack.
- Diamond Offshore Services: Diamond Offshore Services offers a range of maintenance and integrity solutions for offshore assets, including pipe cladding services. They provide weld overlay cladding using high-performance alloys to protect subsea pipelines and risers from corrosion and erosion.
- MetalTek International: MetalTek International specializes in providing metallurgical solutions for various industries, including pipe cladding services. They offer overlay welding and thermal spray coatings using corrosion-resistant alloys to protect steel pipes in harsh environments.
- Ferroglobe PLC: Ferroglobe PLC is a global supplier of silicon and specialty alloys for industrial applications. They offer pipe cladding services using metallurgical bonding techniques to apply corrosion-resistant alloy layers onto steel pipes for chemical processing and petrochemical applications.
These are just a few examples of companies that offer pipe-cladding services. It’s essential to choose a reputable and experienced supplier that can provide high-quality cladding solutions tailored to your project requirements and environmental conditions.
7 Responses
Hi,
We invite you to display your products, innovation, equipment’s, technologies and services at 13th edition of No Dig India Show 2023 to be held on 08 & 09 December 2023 at Chennai Trade Centre, Chennai, Tamil Nadu (India). The event is jointly organized by Indian Society for Trenchless Technology and Construction Industry Development Council (Established by Niti Aayog, Govt. of India).
The event is aimed at the burning need of rehabilitation of buried pipelines for water, sewerage, drainage, oil & gas etc.
The show format includes a conference, exhibition, and 2nd IndSTT Trenchless Excellence Awards Ceremony.
For more details on the event, please visit https://www.nodigindia.com.
For sponsorship and exhibition space booking, please contact undersigned.
Best regards,
Satender Singh Negi
General Manager (Projects)
Indian Society for Trenchless Technology
908, Hemkunt Chambers, 89,
Nehru Place, New Delhi 110019, INDIA
Email: negi@indstt.com
Mob: +91- 9013125123
Web: http://www.nodigindia.com | http://www.indstt.com
Thank you for exploring the subject of pipe lining and sharing with the public. Pipe lining can be also used as a solution for pipe renovation/rehabilitation and to keep them in a good condition – that is called pipe relining. Maybe you would like to look into this topic.
Thanks a lot for sharing this. Pipe Coating is really essential to keep away corrosion.
Nice Blog, Way you describe these for and their difference is really good.
For clad pipes which bonding method is better in Fittings and Pipe ?
Weld overlay process OR explosive bonding method.
Please clarify.
For clad pipes which bonding method is better in Fittings and Pipe Weld overlay process OR explosive bonding method.
Please clarify.
Informative post on Non-metallic coating, After a read I got a clear picture on types of non-metallic coating and able to understand the various pipes used to avoid corrosion. Thank you for sharing the post.