Coating Failure Analysis Study for Gas Pipelines in the UAE
Root Cause Analysis and Coating Assessments for Flowlines and Trunklines within a UAE Gas Facility.
Project Background
Our client, a leading National Oil Company, operates oil and gas production fields across the United Arab Emirates (UAE). The gas reservoirs, developed in different project phases, produce gas gathered through a network of pipelines that are externally coated, cathodically protected, and buried. Penspen was awarded a contract to conduct Root Cause Analysis (RCA) for coating failures affecting flowlines and trunklines within these facilities.
Services
Penspen conducted a detailed analysis to uncover the root causes of coating failures in various types, including 3LPP, 1LFBE, and 2LFBE coatings. Our approach involved laboratory tests such as Hot Immersion Tests, Differential Scanning Calorimetry, and Raman Spectroscopy to identify the causes of failure.
We assessed coating performance under extreme conditions like high temperatures and saltwater exposure typical of Sabkha areas where the pipelines exist and developed methods to detect disbonded coatings. Our evaluation also addressed the impact of solidified sand, reviewed existing specifications for pipeline coatings and cathodic protection.
As a result, the client was provided with a comprehensive gap analysis and actionable recommendations covering coating defects, cathodic protection, inspection programs, and operational considerations to further enhance the safety of their energy assets now and in the future.
Result
With Penspen’s support, our client has significantly enhanced both local and asset safety by reducing pipeline failures and ensuring reliable energy delivery. By addressing coating failures and implementing corrective corrosion protection measures, we have minimised the risk of hazardous leaks and spills. This has enabled enhanced protection of surrounding ecosystems and resulted in substantial cost savings, which can be redirected to community development projects, further benefiting the local communities where our client operates.
Commenting on the project, Arun Behl, Head of Sales & Marketing – East Region said: “”We are proud to have partnered with our client to identify the root causes of coating failures and provide targeted solutions that significantly enhance pipeline integrity. By applying our specialized expertise in coating assessments and root cause analysis, we have not only mitigated risks but also ensured the safe and reliable operation of critical energy assets. This project underscores Penspen’s commitment to delivering value-driven asset integrity solutions that protect both our clients’ operations and the surrounding environment.”