Attachment 1 - Team Project Activities 693JK324RA0001.doc

U.S. Department of Transportation (USDOT)

RA #693JK324RA0001

Pipeline and Hazardous Materials Safety Administration (PHMSA) Attachment #1

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TEAM PROJECT ACTIVITIES

1. Project Discussion with industrial partners and members of academia to seek additional input, develop TAP Team including Peer review members;

2. Kick-off Team meeting and modify the research program, if necessary;

3. Use analytical and finite element analysis to calculate residual stresses in a multi-layer pipeline coating systems. Identify critical coating material properties to the development of residual stresses. The residual stress calculation includes:

(a) Stress distribution along longitudinal direction of a coated pipe joint, particularly at the cutback;

(b) Stress distribution at the metal-coating interface and across the thickness direction;

4. Evaluate the existing residual stress measurement techniques- cantilever beam, instrumented ring, and others and select the most appropriate method for this research;

5. Make residual stress measurement Identify the impact of manufacturing parameters, such as processing temperatures and coating thickness on residual stresses.

The 3L polyolefin coating systems are:

I.

3L HDPE

1.FBE- 4 mil / adhesive-10 mil / HDPE-140 mil

2.FBE-10 mil / adhesive-10mil / HDPE-140 mil

II.

3L PP

1.FBE- 4 mil / adhesive-10 mil / PP-140 mil

2.FBE-10 mil / adhesive-10mil / PP-140 mil

6. Identify and measure the basic coating material properties to be used in the calculation of residual stresses;

7. Compare the calculated residual stress values with the experimental values and refine the analytical modeling to match with the experimental results on residual stresses;

8. Prepare Adhesion test panels. The following surface preparations will be applied:

I- Anchor profile height– 3 mil, 2 mil, and 1.5 mil

II-

Anchor profile shape – angular and round

III-

Peak density – 60, 80, 100 peaks/inch

IV-

Chloride contamination, 20, 30, 40, 50 mg/m2, V- Dust level – Rating 1, 2, 3 in ISO standard 8502-3

VI-

With and without phosphoric acid wash

VII-

Chromate treatment

9. Determine the adhesion degradation rate by immersion of test panels in

(a) 3% salt solution at 60 C for one year;

(b) dry/wet cycling.

Identify the effect of various surface treatments on adhesion durability;

10. Prepare free films of single layer FBE, adhesive, and multi-layer coating;

11. Immerse free films in 60 C 3% salt water to measure their ageing stability, weight and dimensional change vs. time. The total immersion time is one year;

12. Immerse residual stress samples in 3% salt water at 60C and measure the residual stress relaxation rate;

13. Establish the analytical modeling to predict the coating disbondment and identify the critical parameters to coating disbondment;

14. Attend DOT project review meeting;

15. Mid-term team meeting, including Peer review members;

16. Final team meeting including Peer review members;

17. Prepare and submit Monthly reports, Quarterly Status Reports, the Final Project Report, Research Brief and Peer Review Reports; and

18. Publish papers and make presentation.

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