AMI Field Joint Coating Conference - Home | IBIX USA€¦ · Introduction, Technology and Main Pipe Contractors using Flame Spraying • Coating technology objectives • Flame Spraying

Ms. Susanna Giovannini President & CEO

IBIX Srl

(Tecno Supply Division)

AMI Field Joint Coating Conference London 26-27 September 2017

1

•  IBIX – Tecno Supply: Introduction, Technology and Main Pipe Contractors using Flame Spraying

•  Coating technology objectives •  Flame Spraying Field Joints: The Specifications •  What is 3 Layer: 3LPE/3LPP •  Technicalities: Field Joint options •  Flame spray: from manual to automatic systems - coating powders and equipment •  Flame Spraying a Pipe Joint •  Flame Spray: Best Practice, Mechanics of spraying •  Automation •  Projects and references: South Stream Project; ZOHR Gas Field Project •  Semi-automated Flame Spray System •  Automated FJC Equipment •  Summary

2

•  Committed to surface cleaning and surface preparation technologies, industrial coating and anti-corrosion protection

•  Design and manufacturing, R&D and Innovation as driving force for growth

•  Global Patents •  Partnership with Key suppliers (coating powder

formulators, smart hanging, masking, handling solutions providers, testing and certification centers, etc.)

•  Application development with key customers •  Providing technical support and training

Headquarters: Lugo (RAVENNA) - ITALY

Contact: Mr. R. G. Langhans Director North American Headquarters: Tampa, Florida - USA

3

g

Wet & Dry Air abrasion systems

Spotblasting

Portable blasting 3 lt – 60 lt capacity

(0.8 to 15.85 gal)

Automation 4

5

First developer of thermoplastic flame spray coating systems for concrete substrates ( for water/liquid proofing, non-slip coatings, chemical resistant coatings, etc.)

Proprietary technology: Automated Inner Spray

Lining Equipment for Cylinders and

Pipes

g

In Flame Spray Equipment and Thermoplastic Coating Powders since 1997

Automatic thermoplastic coating equipment

First manufacturer designing automated flame spraying

6

-  All Seas (Europe) -  Bredero Shaw -  CCSI – Aegion Group -  CPP (China) -  Donelli (Italy) -  ISOPLUS Mediterranean -  PIH (CRC-EVANS) -  Rae Energy

-  Salzigger, Mannesmann (Hans Tiefenbach)

-  Schneider -  Serimax -  Tenaris (Nigeria) -  VIP (Italy)

7



8

Oil & Gas Coatings & Technologies must deliver:

•  Performance – maintaining the key coating properties: ! Adhesion ! Integrity ! Flexibility

• Reliability • Consistency • Controllability • Repeatability

9



10

•  ISO FDIS 21809-1:2011, main Specification for the 3L system. For use as a class C product (high temperature)

•  ISO 21809-3 2016, sub section of this specification (for field joints) for use as FJC Type 5A (over epoxy)

•  DIN 30 678, covers use of PP as a coating over epoxy and also as a single layer protective system.

•  NF A 49-711, covers use of PP as the top coat in a 3L system. •  Various Oil/Gas company specifications (Total, Gasunie, etc.)

11



12

•  Tough and relatively lower cost •  Flex ib le even at very low

temperature (-70°C) •  Commonly used on overland

pipes particularly in cold climates.

•  Tougher than PE; will resist higher temperature (but not in cold climates)

•  Recognised system for hot pipes •  Sub sea applications.

13



14

•  Will the field joint system stick to the PP or PE on the pipe body? •  Will the FJ system provide the same level of performance as the

pipe body coating? •  How will the field joint coating react to heat when compared to

the PE or PP on pipe body? •  How long will it take to coat the field joint? •  How much $$$$$$$ ?

15



16

•  Historically, flame spray equipment was complicated with blends of Oxygen Propane and Nitrogen and very low volume output.

New Developments: •  Powder formulation

!  MFI tailored to application and performance requirements !  Optimum powder stabilisation to allow passing through a flame without degrading !  Particle size distribution: also to allow passing through a flame without degrading and

maximise transfer efficiency

•  Equipment !  Improved practicality !  Improved spray pattern and speed !  Improved powder flow

17

•  Fully melted coating fused with the existing polyolefin on the pipe body

•  Homogeneous coating that will provide unsurpassed, cost-effective protection.

•  Faster process

Field-applied Flame Sprayed PP & PE coatings using selected powder grades

Factory-applied protective layers on the pipe.

18

•  Ideal for 3LPP, 3LPE, coating of bends, buckle

arrestors and custom fittings.

19

•  Suitable for flame spray applications for pipelines subjected to high temperatures •  Product features include:

!  Full compatibility with adjacent polypropylene coatings in FJC !  Suitability for 3L systems joints over FBE !  Adherence to relevant parts of ISO FDIS 21809-1 Part C and all parts of ISO FDIS 21809-3 !  Adherence to DIN 30678 !  A single layer can perform the same role as a separate adhesive layer and top coat !  It builds up thicknesses > 3mm (118.11 mils) !  OIT > 40 min !  It requires less heat to flow out, avoiding potential yellowing problems !  Reduced particle bounce-off from pipe surface during application, minimising powder loss

20

Product type Polypropylene

Brittle temperature 0°CŦ

Vicat softening point: (ISO 306) ≥ 110°C

Specific gravity (0.93 – 0.96) g/cm3

Hardness (Shore D) 63

Indentation resistance at 23°C ≤0.1mm (4 mils)

Elongation at break 500%

Finished Joint coated with PP10 manual flame spraying

21

•  Suitable for flame spray applications for pipelines subjected to low temperatures •  Product features include:

!  Full compatibility with adjacent polyethylene coatings, in the case of FJC !  Suitability for 3L systems joints over FBE !  Adherence to relevant parts of ISO FDIS 21809-1 Part A and all parts of ISO FDIS

21809-3 !  The ability of a single layer to perform the same role as a separate adhesive layer

and top coat !  The ability to build up thicknesses > 3mm (118.11 mils) !  OIT > 40 min

22

Product type Polyethylene

Brittle temperature -70°C

Vicat softening point: (ISO 306) ≥ 95°C

Specific gravity (0.92 – 0.97) g/cm3

Hardness (Shore D) 53

Indentation resistance at 23°C ≤0.2mm (78.74 mils)

Elongation at break 600%

23

•  Compact, portable and light-weight •  Easy to use, reliable and robust, minimal

maintenance requirements •  Very high powder flow feeding system •  Only requires dry compressed air and LPG •  Powder volume controls on the machine •  Various gun sizes are available to suit

d i f f e r e n t p i p e s i z e s , a l l e a s i l y interchangeable

24

Spray Pattern

•  Old Equipment •  Modern Flame Spray

Low volume in round pattern

High volume in elliptical pattern (normal paint spraying)

25

•  Wide spray pattern (10-12 cm for Spartacus Large Gun)

•  Faster application •  No stripes or powder

build-ups on restricted areas which could result into entrapped air

•  Perfect melting of the powder coat even at high powder feeding rates

26



27

28

Blasting + Induction Heating (Clam Shell

System)

Fusion Bonded Epoxy spraying (Automatic)

Tie Layer (simultaneous

spraying FBE + PP/PE)

PP/PE Top Coat Water Quench



29

•  Adhesion: adhesion of the PP/PE top coat to the fusion bonded epoxy and the factory applied top layer

•  Integrity: the PP/PE film needs to be free from voids, and from layering - highly dependent on the mechanics of spraying

•  Flexibility: integrity is a prerequisite, but flexibility is also determined by the crystallisation process

30

•  When flame spraying, several layers of the plastic material are applied in a molten powder state

•  The molten powder hits the preheated metal surface, which keeps it in the molten state

•  The molten particles need to coalesce, which necessitates the latent heat in the pipe to dissipate through the coating

•  FS PE or FS PP need to be applied layer by layer, and a non homogeneous stratum should never be covered by the successive layer, before it has had the time to coalesce

•  Distance from the flame to the substrate: should be kept constant

31



32

Despite of all the improvements made in Manual Flame Spraying, this system remains dependent on the skills, training and best practice of the applicators.

IBIX has developed an Automated Flame Spray Coating Equipment

Automation offers many benefits.

The resulting BA, bends and field joints will offer an outstanding level of performance.

33

Field Joints

Buckle Arrestors

Bends

34

Objectives & Benefits

Eliminates the “human”

factor

Consistency and

repeatability

Health & Safety

Homogeneous coating

Speed

35



36

PLC & ELECTRIC CABINET The PLC and electric controls will allow the following main functions, among others:

•  Automatic switching ON-OFF of the flames •  Automatic flame setting to the operational

mode •  Automatic powder ON-OFF switching •  Powder flow adjustment and control •  Flame Out safeties featuring flame present

photocells •  Low powder alarm system •  Coating parameters tracking etc.

37

The Flame Spray technology was selected as a better alternative to extrusion

IBIX supplied the full 3LPP system including:

•  FBE spraying (2 guns) •  PP tie-layer flock spraying (2 guns) •  PP Flame Spray (5 guns) •  PP Rough Coat (1 gun)

for a world patent pending system for fully automatic external coating of e.g. buckle arrestors [Schneider].

38

•  Pre-heating in a gas oven •  BAA is taken by a carriage system

then rotates and travels to the 4 coating stations: !  1st coating station – FBE spray !  2nd coating station – PP Flock

Spray (tie-layer) !  3rd coating station – PP Flame

Spray !  4th coating station – PP Flock

Spray (Rough Coat)

•  Water quenching

39



42

•  Objectives: •  Switching on the flame by pressing a button (no manual

igniting device) •  Auto adjustment of air flow for starting flame •  Auto adjustment of air flow for running flame •  Auto adjustment of gas flow

•  Main benefits: •  Improved safety •  Faster set up of flame •  More consistent air/gas flow independent of operator’s

skills •  More stable flame

•  Power supply required: 220 V Single Phase •  Manual flame spray coating: still relying on the operator’s

spraying skills

43



45

46

Electric Cabinet and PLC

3 + 3 sets of guns fixed on 2 opposite arms Transverse and 180° rotation movement of the arms

Main automatic functions The PLC and electric controls will allow the following main functions, among others:

•  Automatic switching ON-OFF of the flames •  Automatic flame setting to the operational mode •  Automatic powder ON-OFF switching •  Powder flow adjustment and control •  Temperature monitoring with pre-set temperature ranges

!  If the coating temperature is lower than or exceeds the pre-set tolerance limits, the powder flow will stop, or flames will stop or cycle will stop (programmable)

•  Thickness measuring (optional, being tested) •  Flame Out safeties featuring flame present photocells •  Project identification •  Coating parameters tracking

47

Spraying parameters: •  Spray pattern with medium size guns (7 cm / 2.7 inch approx.) •  Spraying speed (adjustable) •  Spraying time (adjustable) •  Spraying deposition rate (adjustable)

48

50

•  Pipe diameter: 406 mm (16 inch.) •  1+1 flame spray guns:

!  Cycle time: 3 passes 1.20 mins. each (4 mins. in total) !  Thickness: 3.5 mm approx.

•  2+2 flame spray guns: !  Cycle time: 2 passes 1.20 mins. each (2.40 mins. in total) !  Thickness: 4.8 mm approx. (to reduce the thickness powder flow will be reduced)

Contact Thickness Gauge

On-board laser thickness measuring instrument

51

On-board 4 x digital pyrometers for temperature monitoring

Hand-hold infrared digital pyrometer double checking the current temperature

Status & Schedule •  Pre-operational testing to be completed by October 2017 •  Ready for demonstrations (November-December 2017) •  Ready for field testing thereafter (based on the frame / jig configuration

required by the customer)

•  Different frame configurations for overland, offshore, spool bases possible according to the customer’s requirements and project

52


•  Coating technology objectives •  Flame Spraying Field Joints: The Specifications •  What is 3 Layer: 3LPE/3LPP •  Technicalities: Field Joint options •  Flame spray: from manual to automatic systems - coating powders and equipment •  Flame Spraying a Pipe Joint •  Flame Spray: Best Practice, Mechanics of spraying •  Automation •  Projects and references: South Stream Project; ZOHR Gas Field Project •  Semi-automated Flame Spray System •  Automated FJC Equipment •  Summary 53

•  Starting from the newest flame spray technology and best practice acquired in manual flame spraying, IBIX developed Automatic Flame Spray Equipment for Pipe (BAA) coating, Bend Coating, Field Joint Coating

•  Automated PE & PP Flame Spray Technology for 3L systems offers:

•  Consistency •  Controllability •  Repeatability •  Reliability •  Faster cycle times

•  Eliminates the Human Factor •  Improves Health and Safety

Automated PE & PP Flame Spray Technology becomes a very good alternative to conventional 3LPP & 3LPE coating systems

54

IBIX ITALY EU Headquarters Mrs. Susanna Giovannini President & CEO IBIX Srl Via La Viola 2, 48022 Lugo (RAVENNA) – ITALY Tel. +39 0545 994589 - Fax. +39 0545994567 Email: [email protected] - Web: www.ibix.it Tecno Supply division Email: [email protected] Web: www.tecnosupply.com

53

Documents

AMI Field Joint Coating Conference - Home | IBIX USA€¦ · Introduction, Technology and Main Pipe Contractors using Flame Spraying • Coating technology objectives • Flame Spraying