Attachment 1 - Team Project Activities 693JK326RA001.docx
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- 693JK326RA001
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This is an attachment detailing sample team project activities for a Pipeline Safety Research and Development project funded by the Pipeline and Hazardous Materials Safety Administration (PHMSA) under Research Announcement 693JK326RA001.
The project focuses on analyzing residual stresses in multi-layer pipeline coating systems, specifically 3-layer (3L) polyolefin coatings composed of Fusion Bonded Epoxy (FBE), adhesive, and either High-Density Polyethylene (HDPE) or Polypropylene (PP) layers. Key research activities include: conducting analytical and finite element analysis to calculate and measure residual stresses in coated pipe joints; evaluating existing stress measurement techniques; identifying the impact of manufacturing parameters such as processing temperatures and coating thickness on residual stresses; preparing adhesion test panels with varying surface preparations (anchor profile height, shape, peak density, chloride contamination, dust levels, phosphoric acid wash, and chromate treatment); conducting immersion testing of adhesion test panels in 3 percent salt solution at 60°C and dry/wet cycling for one year to determine adhesion degradation rates; measuring aging stability and dimensional changes of free films; establishing analytical modeling to predict coating disbondment; and preparing monthly reports, quarterly status reports, final project reports, research briefs, and peer review reports. The project includes multiple team meetings with industrial partners, academia, and peer review members, as well as DOT project review meetings and publication of research findings.
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Other files
| File | Type | Posted |
|---|---|---|
| Questions and Answers RFQ 693JK326RA001.pdf | ||
| Attachment 8 - FY26 Basic Agreement Template - FINAL 08122026.docx | DOCX document | |
| Attachment 6 - Title VI Non Discrimination Assurances (DOCR)_FINAL.docx | DOCX document | |
| 693JK326RA001 RA12 Notice FINAL.docx | DOCX document | |
| Attachment 5 - Additional Info 693JK326RA001.docx | DOCX document | |
| Attachment 4 - Budget Summary 693JK326RA001.pdf | ||
| Attachment 2 - Project Deliverables 693JK326RA001.docx | DOCX document | |
| Attachment 7 - Research Topics 693JK326RA001.docx | DOCX document | |
| Attachment 3 - Deliverable-Milestone Schedule 693JK326RA001.xlsx | XLSX spreadsheet |
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Text version
| U.S. Department of Transportation (USDOT) | RA #693JK326RA001 | |
| 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 Technical Advisory Panel 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 High-Density Polyethylene (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 percent salt solution at 60 °C for 1 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 percent salt water to measure their ageing stability, weight, and dimensional change versus time. The total immersion time is one year.
12. Immerse residual stress samples in 3 percent salt water at 60 °C 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.
18. Publish papers and make presentation.
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