Field joint protection: Strategies for safe pipelines
During the Panamanian Corrosion Conference LatinCORR, Jim Kunkle, U.S. Business Development Manager for Seal For Life Industries, shared his experience of more than a decade in the protective coatings industry. From his current position, and at an essential moment for the company, which is integrated into Henkel under the technological umbrella of Loctite, Kunkle stressed the importance of proper field joint protection in energy infrastructure projects.
In an industry where corrosion and mechanical damage are constant threats, pipelines welded joints become the weakest link. The specialist discussed how the combination of preparation, inspection, technology and mechanical protection can make the difference between a reliable system and a costly repair.
In an industry where corrosion and mechanical damage pose constant threats, welded pipe joints become the weakest link. The specialist discussed how the combination of preparation, inspection, technology, and mechanical protection can make the difference between a reliable system and a costly repair.
The vulnerability of field joints
Field joints, located at the ends of each pipe run, are unlined areas that allow pipe runs to be assembled by welding. Once joined, field joints are the most vulnerable point of a pipeline, as they are exposed to risks of corrosion and mechanical wear, especially during the installation and burial process.
Factors such as friction when inserting the pipe into trenches or tunnels, contact with stones or abrasive soils and adverse geotechnical conditions increase the likelihood of damage. For this reason, the surface is prepared, an anti-corrosion coating compatible with the rest of the pipe is applied and, in some cases, additional mechanical protection is added to resist wear and impact.
Preparation and inspection: critical steps
The first barrier to ensuring field joint protection is proper surface preparation. According to Kunkle, this process involves:
- Mechanical preparation: Use of wire brushes to generate a rough surface that favors the adhesion of the coating.
- Chemical cleaning: Application of solvents to remove dust, grease or contaminants.
- Time control: Apply the coating soon after preparing the surface, avoiding dust or humidity to affect the adhesion.
The inspection also plays a key role when backfilling the trench, as the hardness of the coating must be checked to ensure that it has cured sufficiently to resist contact and the weight of the soil. The inspector's experience and the use of non-destructive testing can confirm that the system is ready for operation.
If you prepare a field joint and let it sit, it may be in windy and dusty conditions, so go back again and make sure it is a clean surface before applying the field joint coating.
Jim Kunkle.
Additional protection with SCARGUARD
As mentioned above, after anti-corrosion coatings are applied to the field joint, a mechanical protection layer designed to absorb wear before it reaches the protected surface can also be applied. SCARGUARD®, a product represented by Kunkle, is a system that fulfills this function, being an envelope composed of fiberglass and tri-mesh fabric (textile reinforcement formed by three interwoven layers of fibers) that acts as "insurance" for the field joints.
Its function is sacrificial, i.e. if something wears or breaks, SCARGUARD® will be the layer that protects the steel and not the corrosion coating. This type of protection is especially useful at road crossings, river crossings or rocky areas, where the installation involves a higher risk of abrasion.
The system can wrap not only the joint, but also sections of the main coating, offering comprehensive protection in critical areas. According to Kunkle, avoiding damage in these areas means saving time, cost and hassle, as no one wants to find that, after installation, a pipe has to be dug up and repaired.
Innovation with artificial intelligence
Digitalization and the use of artificial intelligence (AI) are also gaining traction in pipeline inspection and maintenance. While not speaking on behalf of Seal For Life or Henkel's strategy directly, Kunkle shared his insights on how AI can leverage historical construction data, coating performance and operating conditions.
These data, integrated in predictive models, allow anticipating when a section will need maintenance or rehabilitation, providing the ability to predict the optimal time for an intervention, reducing risks and optimizing resources, especially in long-term projects,
Current industry challenges
For Kunkle, one of the most serious challenges is not technological, but the shortage of skilled labor. The high demand for oil, gas and renewable energy projects competes for a limited number of specialized technicians.
Encouraging the entry of new generations, both in field work and in engineering and project management, is essential to maintain the industry's operational capacity. In addition, the specialist recalled that pipelines not only transport hydrocarbons, but also biofuels and renewable gases, which broadens their relevance in the energy transition.
A critical point for the energy industry
Field joint protection is not a minor detail, it is a direct investment in the safety and profitability of a project. From proper surface preparation to incorporating solutions like SCARGUARD® and artificial intelligence tools, every measure helps pipelines withstand the most demanding conditions.
As Jim Kunkle pointed out, the ultimate goal is to ensure that the infrastructure performs its function safely and efficiently throughout its life. In an environment where reliability is critical, attention to these vulnerabilities is a priority that the industry cannot overlook.
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Source: Inspenet.
