€¦ · 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

North America Headquarters www.IBIXUSA.com

Introduction HEADQUARTERS: Largo, FL

Our service / support area

•  USA •  Canada •  Mexico •  Puerto Rico •  Caribbean

•  BVI (British Virgin Island)

•  Trinidad and Tobago •  Bahamas •  Hawaii

•  South America •  Peru

IBIX – TECNO SUPPLY INTRODUCTION & COMMITMENT

•  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

Headquarter: Lugo (RAVENNA) - ITALY

NACE SSPC Swedish* Description N/A SP 1, Solvent Cleaning N/A Removal of oil, grease, dirt, soil and contaminants by cleaning

with solvent, vapor, alkali, emulsion or steam. N/A SP 2, Hand Tool Cleaning St 2 Removal of loose rust, loose mill scale and loose paint by hand

chipping, scraping, sanding and wire brushing. N/A SP 3, Power Tool Cleaning St 3 Removal of loose rust, loose mill scale and loose paint by power

tool chipping, descaling, sanding, wire brushing and grinding.

1 SP 5, White Metal Blast Cleaning

Sa 3 Removal of all visible rust, mill scale, paint and foreign matter by blast cleaning.

3 SP 6, Commercial Blast Cleaning

Sa 2 Blast cleaning until at least two-thirds of each square inch is free of all visible residues.

4 SP 7, Brush-Off Blast Cleaning

Sa 1 Blast cleaning of all except tightly adhered residues of mill scale, rust, and coatings.

SP 8, Pickling Complete removal of rust and mill scale by acid pickling, duplex pickling or electrolytic pickling.

2 SP 10, Near White Blast Cleaning

Sa 2 1/2 Blast cleaning until at least 95% of each square inch is free of all visible rust, mill scale, paint and foreign matter.

N/A SP 11-87T, Power Tool Cleaning to Bare Metal

N/A Removal of all visible rust, mill scale, paint and foreign matter using power tools and producing a minimum profile of 1 mil.

YOUR COATING SUPPLIER ALWAYS DESIGNATES THE DEGREE OF

SURFACE PREPARATION REQUIRED FOR HIS MATERIALS.

THE THREE BASIC STANDARDS USED TO DESCRIBE SURFACE

PREPARATION:

1.  NACE STANDARDS 2.  STEEL STRUCTURES PAINTING

COUNCIL (SSPC) "SURFACE PREPARATION SPECIFICATIONS“

3.  THE SWEDISH PICTORIAL STANDARDS.

IBIX, the best “green” solution for paint and rust removal and special cleaning

•  The IBIX media blasting systems are recognized as the most versatile systems as they work with different media:

IBIX® works with:

•  Natural Garnet,

•  Calcium Carbonate,

•  Sodium Bicarbonate,

•  Vegetal Media

(e.g. nutshell, grinding corn, etc.)

Filters Rolls

APPLICATIONS SODA BLASTING

Food contact parts

Lubricated parts

•  internal blasting of pipes of various diameters (3” minimum)

•  dust-less blasting systems for example for pipe joints

INNOVATIONS & SPECIAL ACCESSORIES FOR SPECIAL NEEDS

IBIX® blasting system has been approved by ATEX for a safe use in Zone 2, gas group IIA, T3, according to EN ISO 80079-36. Abrasive: olivine or similar Technique: blasting with water spray Certified for:

NEW!

INNOVATIONS & SPECIAL NEEDS

MAIN PIPE CONTRACTORS USING IBIX FLAME SPRAY TECHNOLOGY

THERMOPLASTIC POWDERS: FUNCTIONS & ADVANTAGES

•  Barrier Properties

o  Vapour o  Liquids

o  Chemical Resistance

•  Electrical Insulation

o  Anti-corrosion

•  Flexibility o  400-500% elongation

•  No cracking or chipping

•  Thicker coatings o  Barrier properties

o  Edge and weld coverage

o  “Grip” and “warmth”

o  Impact resistance o  500 – 3000 µm (or more with

specific grades) (depending on the polymer type)

•  Eco-friendly

(completely safe during application) •  Approved for contact with food and

drinking water

IBIX POWDER GRADES - PHC & POLYFUSION

For metals coating Concrete, fiberglass and porous substrates

•  CORROSION PROTECTION

•  UV – MARINE – WEATHERING

•  WATER-PROOFING

•  BARRIER COATINGS

•  CHEMICAL PROTECTION (ACIDS – pH 2 to pH 12)

•  Average abrasion o  Metals

o  Concrete + porous substrates

PolyHotCote:

•  Drinking Water and Food contact approval

•  Electric strength test: 47.0 kV/mm measured to IEC 243:1988

•  Adhesive properties to metals: A1 level

•  Salt spray resistance according to ASTM-B 117/85 and ISO 7253: ‒  On steel: adhesion loss < 10 mm after 1000 h ‒  On aluminum: no adhesion loss

•  Hardness according to BS903: ‒  Shore A: 95 ‒  Shore D: 44

•  Environmental Stress Crack resistance according to ASTM D 1693-70: > 1000 h

IBIX POWDER GRADES - PHC & POLYFUSION OFFICIAL CERTIFICATIONS AND TEST RESULTS

•  Impact resistance ASTM D 2794-93 procedure: •  Direct 23°C: 2.7 joules •  Indirect 0°C: 18 joules

•  Abrasion resistance as per ASTM D 4060-90 procedure: after 1000 cycles using H18 abrasive wheels under a 500g load 60 mg of material has been abraded

•  Weathering resistance according to ASTM G 53-88: after 2000 hours no significant loss of gloss or color change

Coating cycle POLYRES + POLYFUSION:

•  Anti-slip Certification according to DIN 51130 - test results: ‒  POLYFUSION smooth version: R9 ‒  POLYFUSION anti-slip version R12

•  Drinking Water and Food contact approval, in the following Countries: ‒  ITALY ‒  SWITZERLAND ‒  FRANCE (awaiting approval)

•  Tensile Strength according to ISO 527:

12 Mpa with tear strength of 22 N/mm

•  Pull-Off Test: ‒  At 500 µ: 5,71 Mpa, GLUE FAILURE ‒  At 1000 µ: 5,80 Mpa, GLUE FAILURE

IBIX POWDER GRADES - PHC & POLYFUSION OFFICIAL CERTIFICATIONS AND TEST RESULTS

IBIX POWDER GRADES - POLYPROP

•  HIGH ABRASION

•  STRONG IMPACT RESISTANCE

•  BARRIER COATINGS

•  HIGHER TEMPERATURE RESISTANCE

•  CHEMICAL PROTECTION (ACIDS – pH 2 to pH 13) – see chemical chart for chemical concentration and max temp For metals coating

•  External corrosion test certificates on grit-blasted steel o  ISO 12944-6 C5M & Im3 High: >15 years when damaged,

most corrosive environments

o  ISO 20340 (Offshore): cyclic corrosion test part of Norsok M-501

o  BAW Im2 & Im3

•  Potable water approvals (see table)

•  Typical applications: o  Ships / marine: pipes, accessories

o  Drinking/Waste water: pipe, fittings and valves

•  Excellent alternative to: o  PA 11 + primer

o  Overdesigned fluoro

o  Multi-layer liquid systems

IBIX POWDER GRADES – PHC-PLUS

MOBILE THERMOPLASTIC POWDER FLAME SPRAY COATING SYSTEMS

•  For metals, concrete, fiberglass and other substrates

•  Fitted with the new CENTURION gun, with Wider Spray Pattern and extra-cooling system.

•  The most suitable system for pipe contractors

•  Ideal for 3LPP and 3LPE, field joints coating, coating of bends and buckle arrestors

•  High volume in elliptical pattern with the patented CENTURION gun

MOBILE THERMOPLASTIC POWDER FLAME SPRAY COATING SYSTEMS

•  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 (minimum 1000 l/min) and LPG

(50-60% propane content at 3 bar pressure) •  Powder volume controls on the machine •  Various gun sizes, all easily interchangeable

•  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.

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS FROM MANUAL TO AUTOMATIC FLAME SPRAYING

•  Ideal for 3LPP, 3LPE, coating of bends, buckle arrestors and custom fittings.

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS FROM MANUAL TO AUTOMATIC SYSTEM

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS FROM MANUAL TO AUTOMATIC SYSTEM

•  Bends coated in PE

Blasting + Induction Heating (Clam Shell

System)

Fusion Bonded Epoxy spraying (Automatic)

Tie Layer (simultaneous

spraying FBE + PP/PE)

PP/PE Top Coat Water Quench

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS FLAME SPRAYING A PIPE JOINT

•  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

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS BEST PRACTICE

•  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

THE FLAME SPRAY TECHNOLOGY IN OIL & GAS MECHANICS OF SPRAYING

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.

AUTOMATION IN FLAME SPRAYING


Field Joints

Buckle Arrestors

Bends


Objectives & Benefits

Eliminates the “human”

factor

Consistency and

repeatability

Health & Safety

Homogeneous coating

Speed

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

•  Automatic switching ON-OFF of the flames

•  Automat ic f lame sett ing 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.

PROJECTS AND REFERENCES SCHNEIDER, GERMANY SOUTH STREAM PROJECT

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].


•  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



PROJECTS AND REFERENCES 3LPE – ZOHR GAS FIELD

•  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

SEMI-AUTOMATED FLAME SPRAY SYSTEM

Spraying parameters:

•  Spray pattern with medium size guns (7 cm / 2.7 inch approx.)

•  Spraying speed (adjustable)

•  Spraying time (adjustable)

•  Spraying deposition rate (adjustable)

AUTOMATED FJC EQUIPMENT

•  Pipe diameter: 21inch •  2+2 flame spray guns:

!  Cycle time: 2 passes 1.20 mins. each (2.40 mins. in total) !  Thickness: 3-3.5 mm approx.

Contact thickness gauge

On-board laser thickness measuring instrument

EQUIPO FJC AUTOMATIZADO

On-board 4 x digital pyrometers for temperature monitoring

Hand-hold infrared digital pyrometer double checking the current temperature

AUTOMATIC FJC COATING EQUIPMENT

•  AUTO FLAME SPRAY SYSTEM HSS

•  Automatic, not dependant on operator •  Perfect melting of PP or PE into the parent coating •  Same performance as the parent coating (3Layer

system) •  Consistent, reliable •  Quality control (temperature, thickness) •  PQT test results repeatable given the •  Repeatable coating parameters •  FASTER •  PE/PP repair with the same products as those originally

used (with the small repair gun)

•  Manual application (heating by manual torches; safety issue)

•  Difficult for larger pipe diameters •  Air entrapped; wrinkles •  Thick HSS need to be pre-conditioned before

application •  Adhesion: Difficult to test •  Long waiting time before testing (24 hours) •  Repairs: long procedure with different products,

feasible only for small areas (10x10 cm) •  Need to stock various HSS sizes

AUTOMATED FJC EQUIPMENT AUTO FLAME SPRAY SYSTEM FOR FJC VS HSS

Typical performace of Flame Sprayed 3LPP/3LPE to ISO 21809-3 2016 Flame Spray 3LPP •  Peel strength: over 13 N/mm • OIT: over 40 min at 220°C • Cathodic Disbondment: max 7

mm disbonding

•  Elongation to break: ≧400 %

Flame Spray 3LPE Peel strength: min 20 N/mm OIT: over 45 min at 220°C Cathodic Disbondment: max 3 mm disbonding Elongation to break: ≧400 %

Flame Spraying for • Homogeneous end to end 3LPE / 3LPP pipe coating system for

• Pipes, Buckle Arrestors • Bends • Fittings • Field Joints • Repairs and rehabilitation on site

Mrs. Susanna Giovannini

Executive Director

Anticorrosion Coating Materials and Equipment IBIX Srl

Via La Viola 2, 48022 Lugo (RAVENNA) –ITALIA

Tel. +39 0545 994589 - Fax. +39 0545994567

E-mail: [email protected] - Web: www.ibix.it

Tecno Supply Division E-mail: [email protected] Web: www.tecnosupply.com

Thank you!for your attention!

Documents

€¦ · 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