Selection of Tests for

Qualifying Coatings for

Aggressive Environments

KTA-Tator, Inc.
August 12, 2020
Learning Objectives:

1. Why performance-based testing should be

used for qualifying coatings,

2. What laboratory test methods are commonly

used to evaluate the performance of coatings
in aggressive environments, and

3. What factors to consider when selecting

between the various specifications such as
ASTM, ISO and NACE for each test method.
Outline
Tests Commonly Used in Oil & Gas

Tests Commonly Used in Wastewater

Tests for Other Aggressive Environments

 What is cathodic
protection?
 A secondary means of
protection to the pipeline
through an impressed
current

What is cathodic
disbondment?
 The loss of adhesion between
the coating and metal substrate
caused by cathodic protection

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 Factors to Consider when Selecting a
Cathodic Disbondment Testing Method

 Sample Shape
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 Temperature
 Qualification
vs
Conformation

Wikipedia

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Comparison of ASTM/ISO/NACE CD Methods
Cell Voltag Solution Duratio
Standard Temperature
Geometry e [aqueous] n
[VCSE] [days]

30, 60 or
ASTM G8 Immersed 1.5 RT Triple salt* 90

ASTM G42 Immersed 1.5 Elevated Triple salt 30

ASTM G95 Attached 3.0 RT 3 % NaCl 90

ISO 15711 Immersed 1.05 RT Sea water 182

NACE Immersed, RT or
1.5 3 % NaCl 28
TM0115 Attached Elevated

*potable tap water with 1 wt% NaCl, Na2CO3, Na2SO4

Immersed Cell CD Resistance Methods

ASTM G8 ASTM G42 modified

Attached Cell CD Methods
ASTM G95 ISO 21809
 Qualification vs Conformance Testing

NACE SP0394
Parameter Qualification Conformance
Duration 28 days 24 or 48 hours
Temperature 20±3°C 65±3°C
Voltage -1.5V SCE -3.5V SCE
Atlas Cell Testing

An Atlas cell is a glass or

metal cylinder containing
a liquid and gas, and offers
testing using pressure and
temperature gradients.
  NACE TM0174, “Laboratory
Methods for the Evaluation of
Protective Coatings and Lining
Materials on Metallic Substrates in
Immersion Service”

 ASTM D6943, “Standard Practice

for Immersion Testing of Industrial
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Protective Coatings and Linings”

ASTM D6943 Method A: Immersion with No
Temperature Gradient
 Coated substrate is mounted to
glass Atlas cell
 Approximately 2/3 of cell is
filled with anticipated service
environment fluid so that liquid
and vapor phases are
represented
 Testing is performed at ambient
room temperature
ASTM D6943 Method B:
Immersion with
Temperature Gradient
 Uses same test set-up
as Method A, but with
applied temperature
gradients
 Interior solution
is heated
 Exterior surface of
substrate is
cooled
ASTM D6943 Method C: Immersion
Testing at Static Temperature and
Elevated Pressure

 Similar set-up to Methods A and

B, but uses an autoclave instead
of glass cell
 Allows for selecting temperature
and pressure that is
representative of the service
environment
Autoclave Testing

“An autoclave is a
pressure chamber used
to carry out industrial
processes requiring
elevated temperature
and pressure different
from ambient air
pressure”.
 NACE TM0185
 Allows most flexibility to
select specific conditions.
 Indicates that hydrocarbon, water,
and gas phases should be used to
Autoclave cover at least 25% per phase, but
allows for the phases,
Testing Methods temperature, pressure, and length
of exposure to be chosen to
simulate the actual service
environment.
 Depressurizationof autoclave is
performed over 15 to 30 minutes.
 NACE TM0185
Evaluations
 Evaluations are not specified which
allows stakeholders to determine
coating performance expectations on
an individual basis.
 Length of testing can be 24 hours or
up to 30 days or longer.
 Evaluations can consist of change
in color and gloss, blistering,
rusting adhesion, and other
defects.
 ISO 15741, Annex C
 Moreregimented than NACE
TM0185.
 Designed to evaluate a coating’s
resistance to cyclic
pressurization.
Autoclave  Autoclave is maintained at ambient
Testing Methods temperature and pressurized to 1,450
psi with nitrogen. Test panels are
subjected to a rigorous 14-day regimen
of cyclically pressurizing and rapidly
depressurizing within 5 minutes.
 Evaluations consist of visual changes
including corrosion, spots, and
blisters, as well as cross-cut adhesion
 Why Rapid
Depressurization?
Performance Testing for Wastewater Service
Severe Wastewater Analysis Testing

Gas phase: 500 ppm H2S, 1% CO2 and 0.5% CH4 in dry air
Liquid Phase: 10% H2SO4 and 0.4% NaCl
Temperature: 65±3°C
Duration: 28 days
Samples held in gas
phase and immersed
Electrochemical Impedance Spectroscopy
Testing for Other
Aggressive Environments

 Abrasion Resistance
 Specific Chemical
Resistance
 High Temperature Resistance
 Corrosion Under Insulation
 Abrasion Resistance

D4060 Taber Abrasion

D968 Falling Sand

G6 Abrasion Resistance
of Pipeline Coatings

G75 Miller Test

Specific Chemical Resistance-
Molten Sulfur Resistance for Railcar Tanks
NACE SP0302. Testing in accordance to
modification of NACE TM0174

(1)6 months molten sulfur exposure at

163°C/ 325°F

(2) Cyclic Test

Exposure to Sulfur + 1.5% Tap Water
1 cycle = 3.5 hours to heat to
325°F
3 hours hold at 325
Allow to cool
25 days or minimum 50
cycles
 High Temperature Resistance
900

800 425°C

700 370°C

600 315°C

500 260°C

400 205°C

300
0 4 8 12 16 20 24 28 32 36 40 44 48 52
56
Corrosion Under Insulation

ASTM G189 Isothermal

Houston Test –
Temperature Range
over Length of
Pipe
Aggressive
Environment
s
Testing should be
representative
of intended service
environments.

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Kaley Stanczyk kst
[email protected]