Fusion Bonded Epoxy Film and Applications for Same
AssigneePipeline Coatings System LLC
InventorsJohn G. Gillen, Don Peter Hart, Jr., Sean Patrick Richardson
Life of this patent
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Abstract
An uncured or partially cured, flexible fusion bonded epoxy (“FBE”) film for application to a metal substrate, such as an oil and gas pipeline pipe and pipeline pipe weld areas includes an epoxy resin, a curing agent, accelerator, filler, and optional additives. The epoxy can include a blend of solid epoxy resin and liquid epoxy resin. Also included are methods of applying the FBE film to pipe in the shop and on field joints. Methods also include using a flexible, electric heat blanket or heat belt to cure FBE film and epoxy liquid coatings on field joints.
Claims26
A partially-cured, flexible fusion bonded epoxy film for application to a substrate, comprising:
- about 40 to 80% by weight epoxy resin;
- about 5 to 25% by weight resin modifiers and tougheners:
- about 3 to 10% by weight curing agent;
- about 1 to 4% by weight accelerator;
- about 20 to 50% by weight filler;
- and
- about 0-1% by weight additives,
- wherein the epoxy film has a thickness of about 0.001 to about 0.05 inches, and the epoxy film has a curing temperature of about 275° F. to about 450° F., and wherein the epoxy resin is a blend of solid epoxy resin and liquid epoxy resin.
A method of coating a pipe to be used in an oil and gas pipeline, comprising:
- providing a piece of pipe;
- preparing the pipe to be coated, comprising sandblasting and heating the pipe within a range of about 400° F. to 475° F. in an oven,
- removing the heated pipe from the oven;
- applying a fusion bonded epoxy film to the heated pipe, wherein the epoxy resin film comprises a blend of solid epoxy resin and liquid epoxy resin, a curing agent, accelerator, filler, and an optional additive that is casted on a plastic backing surface, wherein the applying comprises wrapping the film around the pipe and removing the plastic backing;
- and
- allowing the film to cure into a fusion bonded epoxy coating on the pipe.
A method of coating a field joint of a section of an oil and gas pipeline, comprising:
- welding two pieces of pipe together forming a weld area;
- sand blasting the weld area and an adjacent area that is adjacent to the weld area;
- wrapping a fusion bonded epoxy film having a width around the weld area and the adjacent area and cutting it to fit the weld area, wherein the fusion bonded epoxy film comprises a blend of solid epoxy resin and liquid epoxy, a curing agent, accelerator, filler, and an optional additive that is casted on a plastic backing surface, and wherein the fusion bonded epoxy film is about 0.02 to about 0.05 inches thick;
- removing the plastic backing surface;
- applying a heat source to the weld area to achieve a temperature of at least about 350° F. for about 30 to about 60 minutes;
- and
- removing the heat source.
A method of coating a field joint of a section of an oil and gas pipeline, comprising:
- welding two pieces of pipe together forming a weld area;
- sand blasting the weld area and an adjacent area that is adjacent to the weld area;
- applying a liquid epoxy coating to the weld area by brushing or spraying a two-part liquid coating, wherein one part is a mixture of a liquid epoxy resin and wherein the second part is a liquid amine based curing agent;
- wrapping a woven heat resistant fabric layer comprising nylon, polyester, or a combination thereof around the liquid epoxy coating;
- applying a heat source to the weld area to achieve a temperature of about 100° F. for 5 approximate minutes, followed by heating to a temperature of about 150° F. for 5 minutes, followed by heating to a temperature of about 190° F. for about 20 minutes;
- removing the heat source;
- removing the woven heat resistant fabric layer;
- and
- exposing a fully cured epoxy coating.
Dependencies are inferred from the claim text.