GB2563044A

GB2563044A - Corrosion protection coating

Info

Publication number: GB2563044A
Application number: GB1708716.4A
Authority: GB
Inventors: David Pow Alan
Original assignee: Jiangsu Sun Texx Mat Co Ltd
Current assignee: Jiangsu Sun Texx Mat Co Ltd
Priority date: 2017-06-01
Filing date: 2017-06-01
Publication date: 2018-12-05
Also published as: GB201708716D0

Abstract

A laminate for protecting a substrate comprises a first layer (3, figure 1) and a second layer (2, figure 1) in intimate contact. Both of these layers (2, 3, figure 1) comprise petrolatum material and isobutylene, but the petrolatum materials have different average molecular weights. Preferably, a perforated, thermoplastic film (1, figure 1) is adhered to the layer containing the higher molecular weight petrolatum (2, figure 1). An alternative laminate comprises the first layer 22, and a super-absorbent polymer layer 24. Preferably, the alternative laminate also includes thermoplastic films 23, 25 and an ultraviolet curable epoxy resin layer 26. Methods of forming the protective laminate, possibly on an oil or gas pipe 21, (91, figure 9), using applicators (94, 95, 96, figure 9) on a guide track (93, figure 9) are also claimed.

Description

The present invention relates to coatings for protecting materials from corrosion, methods of producing corrosion protection coatings, and methods of applying corrosion protection coatings.

Surface pipelines for transporting fluids such as oil and gas generally suffer from corrosion caused by moisture in the atmosphere. Buried pipelines or sub-sea pipelines also suffer from corrosion. Pipelines are usually provided with some sort of coating to try to reduce the amount of corrosion.

Thermal plastic shrink wraps have been used to compress a corrosion-inhibiting coating in order to prevent the ingress of water into the coating. However, the heating process required to shrink the wrap of the outer protective layer causes micro rippling of the outer protective layer. The shrinking of the shrink wrap onto the pipe coating is therefore not uniform at the interface with the corrosion protecting material or on the corrodible surface which it is supposed to protect. Micro channels, porosity and micro blisters are formed at the interface during the shrink and the cooling process of shrink wrap. Fluctuation of temperature during heat shrink wrap application, combined with the manual procedures associated with heating in the field or in a workshop environment, also creates variations in the rate and level of shrinking and variations in the compression forces imposed on a protective coating beneath the shrink wrap. Although the micro porosity, trapped air and micro blisters may be small in size they often go undetected and can allow moisture ingress. This may cause corrosion which can cause catastrophic failures in pipelines. This is a particular problem at weld joints and girth welds in oil and gas pipeline installations.

Furthermore, existing protective coatings do not provide a desirable level of corrosion protection, especially when the surface to which they are applied has significant pitting or a complex grain structure.

Existing methods of applying corrosion protection coatings to pipes are inefficient. Furthermore the coatings provided are vulnerable to puncture.

It is amongst the objects of the invention to address one or more of the above problems.

In a first aspect the invention provides a laminate for protecting a substrate from corrosion. The laminate comprises a first layer which comprises a first petrolatum material and a second layer which comprises a second petrolatum material. The layers are in intimate contact.

The average molecular weight of the first petrolatum material may be lower than the average molecular weight of the second petrolatum material. The first petrolatum material may have a lower viscosity than the second petrolatum material. The first petrolatum material may have a lower heat deflection temperature than the second petrolatum material.

The first and second petrolatum materials are semi-solids which contain a mixture of hydrocarbons, usually having chain lengths of over 25 carbon atoms. The petrolatum materials may also contain other components such as mineral oil, waxes, pigments, clays, fillers, corrosion inhibitors and super absorbent polymers. Petrolatum materials are soft, malleable, ductile, non-curing and non-crystalline. Viscosity of petrolatum materials can be controlled by formulation, material selection and by warming or cooling the corrodible substrate to be dressed and protected (or the warming or cooling the petrolatum materials) just prior to the application.

The first layer can be applied directly to a substrate. The low viscosity/molecular weight/deflection temperature of the first layer allows the petrolatum material to penetrate into surface pits on the substrate and into the grain structure. This ensures a bond with the substrate which is resistant to water ingress and therefore reduces corrosion. The softness of the first layer enhances adhesion to a substrate and is more likely to break any electrochemical cells which have formed between the substrate and its surroundings.

The presence of the higher viscosity/molecular weight/deflection temperature second layer provides structural integrity to the laminate and allows easy application of the laminate to a substrate. When the substrate is a pipeline having surface pitting or surface voids, the second layer ensures the laminate remains positioned within the pitting and voids on the surface, whilst still filling the voids or pits effectively. The second layer's higher molecular weight/viscosity/deflection temperature provides rigidity to withstand the linear (thermal) expansion of the pipeline and bridge the surface voids whilst compressing the first layer below into the surface pits or voids.

The first layer may be formulated to provide a high surface tack and have softer 'coldflow' or 'creep' characteristics. The second layer therefore forms a more rigid beam structure over the substrate and compresses the softer first layer into the voids or surface pits.

Preferably at least one, and more preferably both, of the first and second petrolatum materials comprise isobutylene. This improves the self-healing (ie. creep) properties of the layer.

Preferably the first layer comprises a high percentage of petrolatum. Other additives such as ascorbic acid or sulphite may be present as oxygen scavengers. Zinc borate may be present as as a mineral filler with corrosion resistant properties in addition to treated forms of China Clay to provide thixotropic properties. The substances MP 250 or Garamite 1958 or Cetyl Alcohol may be used as rheology additives that create polar activity within the petrolatum material to control viscosity. A small proportion of polyisbutylene having molecular weights consisting of 9500, 2400 and 1300 may be present to provide a mild form of elasticity within the PEM layer.

The laminate may further comprise a thermal plastic film which is bonded to the second layer. The thermal plastic film, when present is bonded to the face of the second layer which faces away from the first layer. The thermal plastic film may provide an additional barrier to water ingress from the substrate's surroundings or draw water through the petrolatum containing layers and away from the surface.

The thermal plastic film may be hydrophobic and non-permeable to water. This is particularly useful when the laminate is applied to a substrate in a dry environment. Since a minimal amount of moisture will be present on the substrate when the laminate is applied, the film functions as a barrier to prevent water from entering the petrolatum containing layers.

The thermal plastic film may be hydrophilic and permeable to water. This is particularly useful when the laminate is applied to a substrate in a wet environment, in which moisture is inevitably present on the substrate when the laminate is applied. The hydrophilic properties of the film draw water through the petrolatum containing layers and away from the substrate.

The thermal plastic film may be provided with apertures to permit the flow of water through the thermal plastic film. The apertures aid the flow of water away from the petrolatum containing layers.

The first and second petrolatum materials may be hydrophobic. This is useful when the laminate is applied in a dry environment as the petrolatum materials will then act as a barrier to prevent water reaching the substantially dry substrate.

The first and second petrolatum materials may be hydrophilic. This is useful when the laminate is applied in a wet environment as the petrolatum materials will then draw moisture away from the substrate. This can be achieved by incorporating super absorbent materials into one or more of the petrolatum containing layers. Preferably the second layer comprises a super absorbent material such as a super absorbent polymer. The second layer may contain superabsorbent hydrogel granules. These aid in the meshing/compatability of the petrolatum containing layers with other layers comprising superabsorbent polymers which may be used in conjunction with the laminate.

The first or second layer may have a thickness of between 200 pm and 1200 pm. This provides a laminate with sufficient corrosion resistant properties whilst remaining economical for large substrates such as oil or gas pipelines.

The laminate may have a thickness of between 1.2 and 3.2 mm. This provides a laminate with sufficient corrosion resistant properties whilst remaining economical for large substrates such as oil or gas pipelines.

In a second aspect of the invention there is provided a laminate for protecting a material from corrosion, the laminate comprising;

a first layer comprising a petrolatum material, and a second layer comprising a super-absorbent polymer.

The first layer provides a good contact with the substrate to be coated whilst the second layer actively draws moisture away from the substrate and holds it within the second layer. The moisture held in the second layer then slowly evaporates as the super-absorbent polymer is warmed either by the sun or by the fluid flowing within a pipeline.

The first layer may comprise isobutylene. This improves the self-healing (ie. creep) properties of the layer.

The laminate may further comprise a thermal plastic film which is bonded to the first layer and between the first and second layers. The thermal plastic film may be hydrophobic and non-permeable to water. The thermal plastic film may be hydrophilic and permeable to water. The thermal plastic film may be provided with apertures to permit the flow of water through the thermal plastic film. The advantages associated with the presence of a film and the properties of the film are discussed above in relation to the first aspect of the invention.

The petrolatum material may be hydrophobic. The petrolatum material may be hydrophilic. To make the petrolatum material hydrophilic, a super absorbent material may be incorporated into the petrolatum containing layer. The advantages associated with these features are discussed above in relation to the first aspect of the invention.

The first layer may have a thickness of between 1.2 and 3.2 mm. This provides a laminate with sufficient corrosion resistant properties whilst remaining economical for large substrates such as oil or gas pipelines.

The laminate according to the first aspect of the invention may further comprise a layer which comprises a super-absorbent polymer and which overlays the second layer. This provides the advantages discussed above in relation to the second aspect of the invention.

The laminate according to either of the first or second aspects of the invention may further comprise a layer comprising a curable polymer which overlays the layer which comprises the super-absorbent polymer. The curable polymer provides mechanical protection to the laminate when it is installed on a substrate.

The curable polymer may be a UV curable epoxy polymer. This allows the epoxy polymer to cured in sunlight or by using a UV lamp to provide a hard coating.

The layer which comprises the super-absorbent polymer may have a thickness of between 2 mm and 6mm. This provides good wicking properties whilst remaining economical for large substrates such as oil or gas pipelines.

In a third aspect of the invention there is provided a method of forming a laminate comprising the steps of;

forming a first layer comprising a first petrolatum material, and applying a second layer which comprises a second petrolatum material over the first layer and compacting the first and second layers so that they are in intimate contact.

The average molecular weight of the first petrolatum material may be lower than the average molecular weight of the second petrolatum material.

The laminate of the third aspect of the invention may be a laminate according to the first or second aspects of the invention.

In a fourth aspect of the invention there is provided a method of forming a corrosion protection coating on a substrate, comprising the steps of;

applying a first layer comprising a petrolatum material to the substrate so that the first layer is in direct contact with the substrate, applying a second layer which comprises a super-absorbent polymer over the first layer, applying a third layer which comprises a curable component over the second layer, and applying a reduced pressure to the three layers and the substrate.

Applying a reduced pressure prevents micro channels, porosity and micro blisters from forming at the interface between the first layer and the substrate. Corrosion prevention properties of the coating are therefore greatly enhanced over heat-shrink wrapped coatings. Preferably no external heating is applied during the reduced pressure step. Preferably the reduced pressure is applied using a vacuum bag. It is though that, surprisingly, the application of a reduced pressure actually agitates the petrolatum material at a molecular level and allows the penetration of the petrolatum material into the grain structure of the substrate, or other very small recesses or voids. This provides a very good bond between the petrolatum material and the substrate and reduces the chances of water ingress and the resulting corrosion.

The reduced pressure may be between 50 kPa and 100 kPa. Preferably the reduced pressure is applied for between 8 and 14 minutes. The time of reduced pressure application may vary depending on the temperature of the underlying pipe to which the layers are applied. The maximum practical application temperature of a petrolatum containing layer to a substrate is around 95 “C. At this temperature only a short period of reduced pressure will be required because the petrolatum is more viscous and seeps more easily into any cavities/recesses. However, a recommended pipe temperature (at application) is below 55“C, for which a longer vacuum application time will be desirable.

The substrate may be a pipe. The substrate and may be a T-section, a bend, a girth weld or a flange joint. The reduced pressure step in these cases is particularly useful as it forces the petrolatum material into features which are at a high risk of corrosion.

The method may further comprise a curing step after the reduced pressure has been applied. This ensures that the curable layer becomes rigid, so as to preserve the enhanced bond between the petrolatum material and the substrate. Mechanical protection is also provided by the curing step.

The curable component may be a UV curable component. The curable polymer may be a UV curable epoxy polymer. This allows the epoxy polymer to cured in sunlight or by using a UV lamp and provide a hard coating.

In a fifth aspect of the invention there is provided an apparatus for applying a corrosion protection coating to a pipe, the apparatus comprising;

a guide, a first dispenser for dispensing a layer comprising a petrolatum material, a second dispenser for dispensing a layer comprising a super absorbent polymer layer, and a third dispenser for dispensing a layer comprising a curable component, wherein the dispensers are moveable along the guide, so that when the guide is positioned adjacent to a pipe, the dispensers may be moved along the pipe in a first direction, and wherein the dispensers are arranged so that when they are moved in the first direction, the first dispenser precedes the second dispenser and the second dispenser precedes the third dispenser. The guide may be a single track or comprise at least two tracks. Each of the dispensers may be a trolley which is adapted to run along the track(s). The fact that the three dispensers are arranged on the guide with the first, preceding the second, which precedes the third means that a protective laminate according the first or second aspects of the invention can be efficiently applied to a pipe. The layer comprising a petrolatum material is applied simultaneously with the layers comprising the super absorbent polymer and the curable component. The dispensers may be moved along the pipe as it is rotated so that the layers are applied one on top of the other.

The apparatus may further comprise a means for rotating a pipe section generally parallel to the guide.

Preferably at least one, and more preferably all three, of the dispensers is a reel. This permits fast application of the layers onto a pipe substrate.

The first dispenser may be provided with a layer comprising a petrolatum material, the second dispenser may be provided with a layer comprising a super absorbent polymer and the third dispenser may be provided with a layer comprising a curable component.

The layer comprising the petrolatum material may be a laminate according to the first aspect of the invention.

The superabsorbent polymers used in the aspects of the invention described above may be in fiber or granular form. Fiber form is preferred as the wicking action of the polymer is improved. Preferably superabsorbent polymers used in the invention contain polymers selected from the group of polyacrylamide copolymer, ethylene malic anhydride copolymer and sodium polyacrylate.

The laminates of the invention may be attached to a carrier layer which is removed prior to use. Preferably the carrier layer is a silicone coated paper.

The curable component or curable polymer of the aspects of the invention described above may be a UV curable polymer having glass fibre reinforcements. This improves the mechanical strength of the material once cured. Preferably the curable component/polymer has a tensile strength of between 50 MPa and 550 MPa.

Preferably the glass fibre reinforcements are between 40 mm and 100 mm in length. Preferably the glass fibres will make up 20% to 48% by weight of the UV curable polymer layer.

Laminates according to the invention may be provided in roll form on a reel or as flat sheets.

Embodiments of the invention will now be described with reference to the figures of the drawings, in which;

Figure 1 is a schematic cross sectional exploded view of a first embodiment of a laminate according to the invention.

Figure 2 is a schematic cross sectional exploded view of a second embodiment of laminate according to the invention.

Figure 3 is a schematic cross sectional exploded view of the laminate shown in figure 2 and the vacuum bag used during its application.

Figure 4 is a schematic cross sectional exploded view of the laminate shown in figure 2 when the outer UV layer has suffered a puncture.

Figure 5 is a schematic cross sectional exploded view of a laminate according to a third embodiment of the invention when the outer UV curable layer has suffered a puncture. Figure 6 is a side view of a pipe girth weld.

Figure 7 is a side view of a pipe T-section.

Figure 8 is a perspective schematic view of apparatus for performing a method according to the invention.

Figure 9 is a pipe dressing apparatus according to the invention.

Figure 1 shows a schematic cross sectional exploded view of a protective laminate according to the invention. The top layer 1 is a thermal plastic film which is hydrophilic and perforated with holes (not shown). The top layer, although shown in an exploded view, is bonded to the layer 2, which is formed of a petrolatum material. The layers 3 and 4 are also formed of petrolatum material, however the average molecular weight of the layer 2 is greater than the average molecular weight of the layer 3. The average molecular weight of the layer 3 is greater than the average molecular weight of the layer 4. This means that the layer 4 is softer than the layers 2 and 3. The layer 2 exhibits 'creep' properties which allow it to fill pits or voids on the substrate to which it is applied. The layer 4 is bonded to a carrier film 5 which is made from silicone coated paper. In use, the carrier film 5 is peeled off the layer 4 just before application and the layer 4 is applied to a corrodible substrate which may be an oil or gas pipe.

It should be noted that although the layers 2, 3 and 4 are shown schematically, intermixing at the boundaries of the layers occurs. This provides a graduated petrolatum material which is unlikely to delaminate and which has progressively softer and more malleable properties closer to the surface 6 which, in use contacts a substrate.

Figure 2 shows a schematic cross sectional exploded view of a protective laminate according to a second embodiment of the invention. The substrate 21 is the wall of an oil or gas pipe. The layer 22 is formed of a petrolatum material which is in direct contact with the pipe's surface. The layer 22 also contains granular and fibrous super absorbent polymer which aids in wicking water away from the pipe's surface. The layer 23 is a thermal plastic film. The layer 24 is formed of super absorbent polymer fibers and has a thickness of 6 mm. This layer may also contain some petrolatum material. The layer 25 is a hydrophobic thermal plastic film which protects the super absorbent polymer layer from the layer 26. The layer 26 is a UV curable epoxy polymer which is reinforced with glassfibre. The polymer is pre-initiated and pre-impregnated. The glass fibres are isotropic and/or a combination of directional Έ and 'C glass fibres. The layer 26 cures within one hour under exposure to UV light.

Figure 3 shows how the laminate shown in figure 2 is applied to a surface. Once all of the layers 22-26 have been applied to the pipe's surface 21, a vacuum bag 27 is fitted over the laminate. The vacuum bag is made from a durable thermoplastic film. Where the film meets the pipe the gap is sealed with a butyl self-tack adhesive mastic 28.

Alternatively the bag may be a silicone self-sealing bag. A spiral breather tube 30 is connected with the interior of the bag and to a vacuum pump (not shown), to remove air from inside the bag. The spiral breather tube is positioned adjacent to the upper surface of the UV curable layer 26 and adjacent to the edges of a breather mesh 29. The breather mesh is positioned over the outer UV curable layer 26 before the vacuum bag is fitted. The breather mesh ensures that airflow to the breather tubes is not hindered and aids extraction of air from within the bag. A vacuum of 50 kPa is applied for between 8 and 14 minutes. The time of vacuum application may vary depending on the temperature of the underlying pipe. The maximum practical application temperature of a petrolatum containing layer 22 is around 95“C. At this temperature only a short vacuum application will be required. However, a recommended pipe temperature below 55“C, for which a longer vacuum application time will be desirable.

After the suitable vacuum application time has passed, the UV curable layer is subjected to UV A-B radiation (whilst still under vacuum).

Figure 4 is a schematic cross sectional exploded view of the laminate shown in figure 2 when the outer UV cured layer has suffered a puncture 41. The super absorbent polymer layer absorbs moisture from the atmosphere through the puncture 41 and swells to fill the puncture. Even toxic water containing heavy metals will be absorbed by the super absorbent polymer. The swelling of the layer 24 minimizes the ingress of water to the pipe's surface even when the protective layer 26 is breached.

Figure 5 is a schematic cross sectional exploded view of a laminate according to a third embodiment of the invention when the outer UV cured layer has suffered a puncture. The puncture has penetrated through the UV curable layer 58, the hydrophobic thermal plastic film 57, the super absorbent polymer layer 56, the thermal plastic film 55 and into at least one of the layers 54, 53 and 52 which comprise different petrolatum containing materials. The top petrolatum containing layer 54 creeps to seal the breach in the thermal plastic film layer and into the super absorbent polymer layer 56. The top petrolatum containing layer 54 contains superabsorbent hydrogel granules. These aids in the meshing/compatability of the petrolatum containing layer 54 with the superabsorbent polymer layer 56. The speed of the self-healing (creep) will depend upon the pressure that the petrolatum containing material is under. This can be tuned by adjusting the pressure of the vacuum application, when this method of application is utilized. A high pressure will generally lead to fast healing properties. The superabsorbent polymer layer also absorbs moisture from the surroundings through the breach 59 and thereby swells to fill the breach in the UV cured layer.

Figure 6 shows a section 61 of a pipe used in an oil pipeline which has a girth weld 62. These areas of a pipeline are particularly vulnerable to corrosion and will benefit from the laminates and methods described herein.

Figure 7 shows a section 71 of a pipe used in an oil pipeline which is a T-splitter section and which is provided with flanges 72. The walls 73 of the pipe at the T- splitter section are curved. These areas of a pipeline are particularly vulnerable to corrosion and will benefit from the laminates and methods described herein.

Figure 8 is a perspective schematic view of apparatus for performing a method according to the invention. The apparatus comprises three Z blade mixing chambers 81,82 and 83, each of which contains a different formulation of petrolatum material. Petrolatum material is conveyed from each of the mixing chambers to the conveyor table 84 via conduits 85, 86 and 87 which contain reversible screw injectors (not shown). The reversible screw injectors control the feed of the petrolatum material to the conveyor table. Petrolatum material is deposited on the conveyor table through one or more of the doctor boxes 88, 89 and 90. The petrolatum material passes under precision rollers 91 and 92 which compress the petrolatum material into a thin layer 93. On the conveyor table the layer of petrolatum material may be slit to a desired width. The conveyor table is heated or cooled to preserve the viscosity of the petrolatum layer. Chilled or heated air fans (not shown) may be positioned above the table for this purpose. Petrolatum materials can generally be mixed at temperatures from 62“C to 185“C.

Petrolatum laminates having up to three layers of different petrolatum materials may be formulated by applying different formulations of petrolatum material in sequence to the conveyor table. The temperature of the conveyor table is chosen so that the different petrolatum layers are soft enough to ensure that a strong bond is formed between the layers. Once formed the layers are provided with a carrier film 94 which is typically silicone coated paper and is dispensed from a reel 95 and meets with the petrolatum layer 93 on the conveyor table. The petrolatum layer and carrier layer are would onto a collection reel 96. The collection reel is then removed and cooled until the petrolatum material is viscous enough for storage. Further reels 97 and 98 containing pre-rolled layers of petrolatum material may be provided in order to feed pre-rolled layers of petrolatum material onto the conveyor table in order to combine the pre-rolled layers of petrolatum material with a further layer of petrolatum material having a different viscosity or molecular weight or deflection temperature, according to the present invention.

Figure 9 shows a pipe dressing apparatus according to the invention. A pipe section 91 is held on supports 92 which are adapted to rotate the pipe section about its longitudinal axis. An elongate metal track 93 is provided generally parallel to the pipe section. Three dressing stations 94, 95, 96 are provided on the track and are moveable along the track. The first dressing station 94 is provided with a reel 98 holding a strip of petrolatum containing material 99, which may be a multi-layer petrolatum containing material according to the present invention. The end of the strip of petrolatum containing material is attached to the pipe section at a first end 97 of the pipe section. The pipe is then rotated and concurrently the dressing station 94 is moved along the track so that the pipe section is wrapped in the petrolatum containing material. Once a portion of the pipe has been coated, the end of a strip of superabsorbent polymer containing material 100 (attached to a reel 101 on the second dressing station 95) is attached to the first end 97 of the pipe section so that it overlays the layer of petrolatum containing material. The rotation of the pipe is continued and the dressing stations 94 and 95 are moved along the track to further coat the pipe in a superabsorbent polymer layer, over the petrolatum containing layer.

A similar process is followed for overlaying a UV curable epoxy polymer layer 102 over the superabsorbent polymer layer using the reel 103 and the dressing station 96.

Once the pipe has been coated in the 3 layers, it may be subjected to a vacuum application using a vacuum bag (not shown). The pipe section may then be cured using a UV light 106 attached to a track 105 which runs alongside the pipe 104. Supports 107 may be provided for rotating the pipe so that the UV curable coating is evenly cured.

Claims

1. A laminate for protecting a substrate from corrosion, the laminate comprising; first layer which comprises a first petrolatum material, and second layer which comprises a second petrolatum material, wherein the average molecular weight of the first petrolatum material is lower than the average molecular weight of the second petrolatum material, and wherein the first and second layers are in intimate contact.

2. The laminate according to claim 1 wherein at least one of the first and second petrolatum materials comprises isobutylene.

3. The laminate according to either preceding claim further comprising a thermal plastic film which is bonded to the second layer.

4. A laminate according to claim 3 wherein the thermal plastic film is hydrophobic and non-permeable to water.

5. A laminate according to claim 3 wherein the thermal plastic film is hydrophilic and permeable to water.

6. A laminate according to claim 5 wherein the thermal plastic film is provided with apertures to permit the flow of water through the thermal plastic film.

7. A laminate according to claim 4 wherein the first and second petrolatum materials are hydrophobic.

8. A laminate according to claim 5 or 6 wherein the first and second petrolatum materials are hydrophilic.

9. A laminate according to any preceding claim in which the first or second layer has a thickness of between 200 pm and 1200 pm.

10. A laminate according to any preceding claim having a thickness of between 1.2 and 3.2 mm.

11. A laminate for protecting a material from corrosion, the laminate comprising; a first layer comprising a petrolatum material, and a second layer comprising a super-absorbent polymer.

12. A laminate according to claim 11 wherein the first layer comprises isobutylene.

13. A laminate according to either of claims 11 or 12, further comprising a thermal plastic film which is bonded to the first layer and between the first and second layers.

14. A laminate according to claim 13 wherein the thermal plastic film is hydrophobic and non-permeable to water.

15. A laminate according to claim 13 wherein the thermal plastic film is hydrophilic and permeable to water.

16. A laminate according to claim 15 wherein the thermal plastic film is provided with apertures to permit the flow of water through the thermal plastic film.

17. A laminate according to claim 14 wherein the petrolatum material is hydrophobic.

18. A laminate according to either of claims 15 or 16 wherein the petrolatum material is hydrophilic.

19. A laminate according to any of claims 11-18 wherein the first layer has a thickness of between 1.2 and 3.2 mm.

20. A laminate according to any of claims 1 -10, further comprising a layer which comprises a super-absorbent polymer and which overlays the second layer.

21. A laminate according to any of claims 11 -20, further comprising a layer comprising a curable polymer which overlays the layer which comprises the superabsorbent polymer.

22. A laminate according to claim 21 wherein the curable polymer is a UV curable epoxy polymer.

23. A laminate according to any of claims 11 -22 wherein the layer which comprises the super-absorbent polymer has a thickness of between 2 mm and 6mm.

24. A method of forming a laminate comprising the steps of; forming a first layer comprising a first petrolatum material, and applying a second layer which comprises a second petrolatum material over the first layer and compacting the first and second layers so that they are in intimate contact, wherein the average molecular weight of the first petrolatum material is lower than the average molecular weight of the second petrolatum material.

25. A method of forming a laminate according to claim 24, wherein the laminate is a laminate according to any of claims 1-10.

26. A method of forming a laminate according to claim 24, wherein the laminate is a laminate according to any of claims 11-23.

27. A method of forming a corrosion protection coating on a substrate, comprising the steps of;

28. A method according to claim 27 wherein the reduced pressure is between 50 kPa and 100 kPa.

29. A method according to either of claims 27 and 28 wherein the substrate is a pipe.

30. A method according to any of claims 27-29 wherein the substrate is a T-section, a bend, a girth weld or a flange joint.

31. A method according to any of claims 27-30, further comprises a curing step after the reduced pressure has been applied.

32. A method according to any of claims 27-31 wherein the curable component is a UV curable component.

33. Apparatus for applying a corrosion protection coating to a pipe, the apparatus comprising;

a guide, a first dispenser for dispensing a layer comprising a petrolatum material, a second dispenser for dispensing a layer comprising a super absorbent polymer layer, and a third dispenser for dispensing a layer comprising a curable component, wherein the dispensers are moveable along the guide, so that when the guide is positioned adjacent to a pipe, the dispensers may be moved along the pipe in a first direction, and wherein the dispensers are arranged so that when they are moved in the first direction, the first dispenser precedes the second dispenser and the second dispenser precedes the third dispenser.

34. An apparatus according to claim 33 wherein at least one of the dispensers is a reel.

35. An apparatus according to either of claims 33 or 34 wherein the first dispenser is provided with a layer comprising a petrolatum material, the second dispenser is provided with a layer comprising a super absorbent polymer and the third dispenser is provided with a layer comprising a curable component.

36. An apparatus according to claim 35 wherein the layer comprising the petrolatum material is a laminate according to any of claims 1-10.