Failure of Fusion-Bonded Epoxy Internal Coatings in Sour Condensate Piping: A Case Study on Methanol-Induced Degradation and Asset Integrity Loss

Abstract This paper provides a detailed technical case study examining the catastrophic failure of internal Fusion-Bonded Epoxy (FBE) coatings on carbon-steel process piping used for sour-hydrocarbon condensate transfer within Kuwait Oil Company (KOC) facilities. This protective system, commonly used throughout the oil and gas industry, experienced premature degradation and complete detachment. The cause was identified as a chemical incompatibility, where methanol used as an essential hydrate inhibitor during winter operations chemically attacked and softened the FBE polymer matrix. The consequences included severe operational problems, such as equipment blockages caused by peeled coating debris and accelerated corrosion of the now-exposed carbon steel piping, with corrosion rates exceeding 1 mm per year. This failure compromised asset integrity and posed significant safety risks. The primary aim of this paper is to share the key lessons learned about material incompatibility, offering actionable insights and detailing the corrective and preventive measures implemented by KOC to avoid similar catastrophic failures and to ensure long-term integrity and safety in sour hydrocarbon systems.