Many businesses use steel pipes, valves, and connectors to move fluids and do other important jobs. But Rust is one of the biggest problems they often have to deal with.
Rust can damage pipes and make replacements and repairs very expensive. Additionally, the good news is that coats and linings aren’t the only ways to keep pipes from rusting.
However, this guide is about Fusion Bonded Epoxy (FBE) covering, a popular and effective way to keep pipes from rusting.
What is FBE Coating?
Fusion Bonded Epoxy (FBE) coating—also known as powder coating—is the industry standard for oil and gas, water, sewage, and other industries. It is a thermosetting resin coating that is applied to steel pipes.
An FBE coating prevents corrosion in pipes by coating both the inside and outside of the pipe. Additionally, FBE coating can also protect the lines from abrasion and damage due to friction. Moreover, it is a cost-effective way to protect pipes and lasts many years.
Additionally, check out; “ID Pipe Coating Process: How Does it Work?.”
Advantages of FBE
In the realm of industrial applications, durability and reliability are paramount. When equipment and components fail, it can lead to costly downtime, safety hazards, and production disruptions.
Moreover, to address these concerns, FBE (fusion-bonded epoxy) coatings have emerged as a preferred solution, offering a range of advantages that make them an ideal choice for various applications.
Durability Against Corrosion and Abrasion
FBE coatings are renowned for their exceptional resistance to corrosion and abrasion, two of the most common causes of equipment failure in harsh environments. The unique properties of FBE, such as its high cross-link density and chemical inertness, create a formidable barrier against aggressive chemicals, solvents, and mechanical wear.
This durability translates into extended equipment lifespan, reduced maintenance costs, and enhanced operational efficiency.
Superior Adhesion and Bonding
FBE coatings exhibit exceptional adhesion and bonding strength to various substrates, including steel, concrete, and fiberglass. This strong bond ensures the coating remains intact even under extreme conditions, preventing peeling, flaking, or delamination.
This adherence further contributes to the longevity of the coated surface and protects against the ingress of corrosive substances that could undermine the integrity of the underlying material.
Resistance to High Temperatures and Thermal Cycling
We engineer FBE coatings to withstand high temperatures and thermal cycling, making them suitable for extreme heat exposure applications. The exceptional thermal stability of FBE prevents the coating from degrading or softening under intense heat, ensuring its protective integrity even in the most demanding environments.
Additionally, this resistance to thermal cycling also prevents the coating from cracking or warping, further extending its lifespan and enhancing its protective capabilities.
Electrical Insulation Properties
FBE coatings possess excellent electrical insulation properties, making them ideal for protecting electrical components and equipment from short circuits and other electrical hazards.
Furthermore, the high dielectric strength of FBE effectively isolates electrical conductors and prevents the passage of electrical current through the coating, ensuring the safe operation of electrical systems in demanding environments.
Cost-Benefit Analysis
The initial cost of FBE coating can be higher than other coatings. However, the long-term cost savings from reduced maintenance and extended equipment lifespan can make FBE coating a more cost-effective solution in the long run.
Furthermore, the application of FBE coating can be more expensive than other coatings due to the specialized equipment and expertise required.
We must properly prepare the surface of the substrate before applying FBE coating. However, this can add to the overall cost of the project.
Versatility Across Diverse Applications
FBE coatings find applications in various industries, including oil and gas, chemical processing, power generation, and water and wastewater treatment. Additionally, their versatility stems from their ability to withstand harsh environments, corrosion and abrasion resistance, and excellent electrical insulation properties.
Moreover, FBE coatings contribute to enhanced safety, reduced maintenance costs, and extended equipment lifespan in these industries.
Environmental Considerations
FBE coatings are formulated with low-VOC (volatile organic compound) resins, making them an environmentally friendly choice. This reduced VOC content minimizes air pollution and environmental impact during application and curing.
Additionally, FBE coatings offer long-term protection against corrosion and abrasion, reducing the need for frequent repainting and associated environmental impacts.
FBE Coating Techniques
All three FBE coating techniques create a strong, durable, long-lasting coating. The choice of technique depends on the specific application and the desired finish.
There are three main FBE coating techniques:
Electrostatic Spray
This is the most common method of applying FBE coating. The FBE powder becomes electrostatically charged, attracting it to the grounded steel surface. This creates a uniform and even coating.
Fluidized Bed
In this method, we fluidize the FBE powder in air. This means we suspend the powder particles in the air and behave like a fluid. Additionally, the fluid powder is then sprayed onto the hot steel surface.
Rotary Atomization
In this method, we atomize the FBE powder into a fine mist using a rotary atomizer. The mist of powder is then sprayed onto the hot steel surface.
FBE Coating Problems
Fusion-bonded epoxy (FBE) is a durable, long-lasting coating that can be susceptible to problems if not correctly applied or maintained. Here are some of the most common FBE coating problems:
Poor Adhesion
Poor adhesion is a common problem with FBE coatings. Several factors can cause this, including:
- Improper surface preparation
- Contamination of the steel surface
- Incorrect application of the FBE coating
- If the FBE coating does not adhere properly to the steel surface, it can peel off or blister, exposing the steel to corrosion.
Voids and Bubbles
Voids and bubbles can also occur in FBE coatings. These are caused by air or moisture that is trapped in the coating during the application process. Moreover, voids and bubbles can weaken the coating, making it more susceptible to damage.
Pinholing
Pinholing is a problem that occurs when tiny holes form in the FBE coating. Furthermore, several factors can cause these holes, including:
- Improper application of the FBE coating
- Contamination of the steel surface
- Damage to the coating during handling or transportation
- Pinholing can allow moisture and corrosive substances to penetrate the layer, leading to corrosion of the underlying steel.
Chalking
Chalking is a problem that occurs when the FBE coating begins to break down and turn into a powdery substance. Additionally, exposure to ultraviolet (UV) radiation causes this. Chalking can make the coating appear unsightly and more susceptible to damage.
Cracking
Cracking is a severe problem that can occur in FBE coatings. Several factors cause this, including:
- Stress on the coating
- Exposure to extreme temperatures
- Improper application of the coating
- Cracking can expose the underlying steel to corrosion and make the layer more susceptible to damage.
Overcuring
Overcuring is a problem that can occur when the FBE coating is cured for too long or at too high a temperature. This can cause the coating to become brittle and crack.
Undercuring
Undercuring is a problem that can occur when the FBE coating is not cured for long enough or at a low enough temperature. This can cause the coating to be soft and sticky.
Contamination
Contamination of the steel surface or the FBE coating can cause several problems, including poor adhesion, voids, and pinholing.
Improper Handling and Storage
Improper handling and storage of FBE coatings can damage the coating and make it more susceptible to problems.
Additionally, we suggest reading out; “How to inspect welding Joints?.”
Conclusion
FBE coatings have become preferred for industrial applications demanding durability and reliability. Additionally, their exceptional resistance to corrosion, abrasion, high temperatures, and strong adhesion and electrical insulation properties make them an ideal choice for protecting a wide range of equipment and components in diverse industries.
Furthermore, by embracing FBE coatings, organizations can enhance the longevity of their assets, reduce maintenance costs, and promote sustainable practices.
FAQs
Q1: What is the purpose of FBE coating?
Ans: Fusion-bonded epoxy coating, sometimes called FBE coating or fusion-bond epoxy powder coating, is a popular epoxy-based powder coating applied to steel pipes used in pipeline construction to prevent corrosion.
Q2: What are the properties of fusion-bonded epoxy?
Ans: Better resistance to coming apart and excellent dielectric qualities. How well it resists heat and damage from rusting over time. Moreover, strong resistance to things in the environment, like acidic grounds, salt water, microorganisms, and plant roots that get through.
Q3: What is the maximum temperature for FBE coating?
Ans: The maximum temperature for FBE coating is between 350° F and 500° F.
Q4: What is the need and importance of powder coating?
Ans: The purpose of acrylic paint is usually to produce a hard, durable finish. However, we mostly use powder coating on metals like car frames, bicycle frames, aluminum extrusions, home appliances, and drum gear.
Q5: What is the difference between Aro and FBE coating?
Ans: On the first hand, we use FBE as the bottom layer in a multi-coating system. It is the main corrosion protection layer. On the other hand, ARO is a thermosetting powder coating put on top of a proper FBE to protect it while it is being handled, stored, and put in place.
