Volume 29 - Number 1 - Denso 29 - Number 1 ... training, applicator certification, ... Buried Steel Coating Corrosion Prevention for Pipeline Joints - New Zealand

LEADERS IN CORROSION PREVENTION & SEALING TECHNOLOGY

Volume 29 - Number 1

Denso Protal 7250 being applied to a crude oil pipeline in Canada - see story page 6-7.

2

WINN & COALES INTERNATIONAL LTD

WINN & COALES (DENSO) LTD Tel: +44 (0) 20 8670 7511Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Anti-corrosion and sealing systems Email: [email protected]

Website: www.denso.net

ARCHCO-RIGIDON Tel: +44 (0) 20 8761 6244Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Corrosion resistant linings Email: [email protected]


DARTFORD COMPOSITES LTD Tel: +44 (0) 1322 350097Unit 1, Ness Road, Erith, Kent DA8 2LD Fax: +44 (0) 1322 359438✓ Manufacture and repair of FRP panels for cars and trains Website: www.dartfordcomposites.co.uk

DENSO NORTH AMERICA INC - CANADA Tel: +1 416 291 343590 Ironside Crescent, Unit 12, Toronto, Ontario, M1X 1M3 Fax: +1 416 291 0898Canada Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.densona.com

DENSO NORTH AMERICA INC - USA Tel: +1 281 821 33559747 Whithorn Drive, Houston, Texas 77095 Fax: +1 281 821 0304United States of America Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.densona.com

DENSO SOUTH AFRICA (PTY) LTD Tel: +27 31 569 4319 120 Malacca Road, Redhill Industrial Area, Durban North 4051, Fax: +27 31 569 4328Republic of South Africa Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.denso.co.za

DENSO (AUSTRALIA) PTY LTD Tel: +61 1300 658 590411-413 Victoria Street, Brunswick, Victoria 3056, Fax: +61 1300 655 064Australia Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

DENSO (NEW ZEALAND) LTD Tel: +64 9274 1255PO Box 76167, Manakau City, Auckland, Fax: +64 9274 1258New Zealand Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

SEASHIELD INTERNATIONAL Tel: +44 (0) 20 8670 7511Denso House, Chapel Road, London SE27 OTR, England Fax: +44 (0) 20 8761 2456✓ Marine corrosion protection systems Email: [email protected]


SEASHIELD INTERNATIONAL Tel: +1 281 821 33559747 Whithorn Drive, Houston, Texas 77095 Fax: +1 281 821 0304United States of America Email: [email protected]✓ Marine corrosion protection systems Web site: www.densona.com

SEASHIELD INTERNATIONAL Tel: +61 1300 658 590411-413 Victoria Street, Brunswick, Victoria 3056, Fax: +61 1300 655 064Australia Email: [email protected]✓ Marine corrosion protection systems Website: www.densoaustralia.com.au

SEASHIELD INTERNATIONAL Tel: +64 9274 1255PO Box 76167, Manakau City, Auckland, Fax: +64 9274 1258New Zealand Email: [email protected]✓ Marine corrosion protection systems Website: www.densoaustralia.com.au

PREMIER COATINGS LTD Tel: +44 (0) 1233 770663Headcord Road, Smarden, near Ashford, Fax: +44 (0) 1233 770633Kent TN27 8PJ, England Email: [email protected]✓ Membranes and corrosion protection systems Website: www.premiercoatings.com

For further information on our products and their suitability for your particular project,please contact any of the Denso companies listed below:

Accident Prevention in New Car Showroom - United Kingdom


3

Denso Anti-Slip TapeImproves Safety in

New Car ShowroomAs an aid to Health and Safety requirements, Denso Anti-SlipTape has been applied to two key areas in the new prestigeReading garage that is stocking Japanese Infiniti cars.

A total of some 250m2 of the50mm wide tape has been appliedby specialist contractors BDBDesign Build of Sheffield. One keyarea is in the service bay and theother on the emegency fire escapewalkway. The tape has beenchosen and supplied in blackand yellow chevron (hazard)and plain yellow colours.

Denso Anti Slip Tape comprisesa self-adhesive PVC Tape coatedon one surface with a layer ofacrlyic adhesive. The uppersurface is coated with acontinuous layer of aluminiumoxide particles. It is available inseveral colours and supplied in18m roll form. The adhesivesurface is protected by a plasticfilm interleaving which isdiscarded during application.

This recently introducedDenso product is designed forboth indoor and outdoor use.As well as garage floors it canalso be used to enhance safety onsteps, paths, patios, decking anda multitude of other areas.

Country: United Kingdom

Location: Reading

Object: Showroom floor

Problem: Accident prevention

Product Denso solution Anti-Slip Tape

Project Summary

Product type:Industrial Safety Tape

For quick identification of the relevantproduct type used in each story we

have used the following colour codes:

BURIED PIPELINES & LPG VESSELS

EXPOSED STEEL & PIPEWORK

STORAGE TANKS, PUMPS ETC

SEALING MASTICS

MEMBRANES & FLASHINGS

INDUSTRIAL TAPES

SUB SEA PIPELINES & JETTY PILES

Protective coatings for......

Protective linings for.....

Sealing & waterproofing.....

Above: The new prestige Infiniti car showroom in Reading.Below: Denso Anti-Slip Tape used in the service bay and emergency walkways (inset).

4


Corrosion Prevention for Iron Mill Condensers - Korea

Archco-Rigidon LiningChosen to Solve CondenserCorrosion ProblemEngineers at a major iron mill located in Gwangyang, Koreawere experiencing a series of corrosion problems withthe mill condensers.

As replacement would be anexpensive and time cunsumingoperation, Densoʼs Koreanagent, K-Cotech suggestedrepairing the damagedcondensers with anArchco-Rigidon 402B(423D) and502B(523D) liquid lining system.

The condensers were first gritblasted to remove the old FRPcoating and then primed.A filler coat was used to fill thewinding section and thenArchco-Rigidon 402B lining wasapplied over the damaged areas.

When the system wascompleted the iron mill engineerswere delighted at the results.

Country: Korea

Location: Gwangyang

Object: Mill condensers

Problem: Corrosion prevention

Product Archco-Rigidonsolution: 402B & 502B

Project Summary

Product type:Industrial Lining

Photos:

Top: The badly corroded condensers.

Below: The problem is solved using the Archco-Rigidon lining system.


5

Corrosion Prevention for Gasolene Pipeline - Japan

Densyl Tape Protects GasoleneLoading Station Pipework

Country: Japan

Location: Unspecified

Object: Gasolene pipes


Product Densyl Tapesolution: System

Project Summary

Product type:Exposed Surface Coating

A Densyl Tape System was used to give effective corrosionprevention to selected pipework located at a Japan Energygasolene loading station.

All joints and flanges on the pipework sections chosen for the Densosystem, were filled with Densyl Mastic to give a smooth profile prior towrapping with Densyl Tape. The conformity, flexibility and acceptably neatfinish of the petrolatum tape system is perfectly demonstrated in thephotographs below.

6


Corrosion Prevention for Crude Oil Pipeline - Canada

After a pipeline is buried andcommissioned its life begins, andduring the course of which thepipeline will be subject to manyforms of inspections, evaluationsand resulting treatments. Basedon a wide variety of variablecircumstances and environmentsa pipelineʼs physical conditionwill deteriorate over time andsubsequent remedies must beapplied in order to bring it backto its original health.The following is a snapshot intime of one such situation onCanadaʼs largest liquids pipelinetransmission system.

One form of pipelineinspection is the use of ʻSmartpigsʼ. ʻSmart pigsʼ or internalinspection tools are mechanicaldevices that are inserted intoone end of a pipeline and thenproceeded to travel down thesection of pipe to be inspected.After the desired length ofpipeline is travelled, theinspection tool is dischargedfrom the pipeline havinggathered data which helpstechnicians diagnose thecondition of the pipeline.Inspection methods such asUltrasonics (UT) and MagneticFlux Leakage (MFL) arecommonly used to pinpointweaknesses in the pipeline, alarge part of which are causedby corrosion. In this particularscenario the owner company rana MFL tool through sections ofpipeline stretching hundreds ofkilometers and as a result of the

Aiding in the Health of a PipelineCanada’s abundance of oil is primarily in Western Canada and must travel great distances inorder to bring this natural resource to market. A massive infrastructure of pipelines is in placewhere many thousands of kilometers of small diameter liquids production piping eventuallyends up flowing into much larger diameter transmission piping which brings crude oil torefineries and refined product to bulk terminals and tank farms across Canada and theUnited States of America.

inspection, potential problemswere identified in a few locations.The next phase of the projectwas to expose the sections ofburied pipeline where the ʻsmartpigʼ had logged anomalies,

remove the existing coating andperform a more detailedinspection on the problem areasand determine a correctivecourse of action. Once finalvisual and technical evaluations


7

Corrosion Prevention for Crude Oil Pipeline - Canada

of the pipeline were performed,the identified areas were eitherreinforced with weld-onmechanical steel sleeves (whichwas the norm) or deemed insatisfactory condition. At theend of the inspection process allareas needed to be re-coatedbefore back-filling the pipelinewhich is where Densogot involved.

Working with the ownercompany, third party inspectionand the coatings applicatorDenso came to the tableproviding technical advice andthe proper materials to reinstatethe health of the pipelinescoating system. The systemneeded had to be one that couldbe applied in the field undervarying conditions on a pipelinethat was in operation. For thissurgery, the Denso Protal 7250was utilized on the majority of

the length of pipeline that hadbeen stripped of the originalthree-layer polyethylene coating.After a short period and after the7250 epoxy had set, the finalrequirement of the surgicaloperation required the newlyinstalled 7250 be tied into theexisting three-layer polyethylenecoating at either end of therepair. This last step wasaccomplished by using Denso

Country: Canada

Location: Countrywide

Object: 42” diameter crude oil pipeline


Product Denso Protal 7250, Denso Hotline Tape andsolution: Denso Glasswrap Outerwrap

Project Summary

Product type: Buried Steel Coating

Hotline Tape to transition the twocoatings and to ensure strongmechanical protection on the 42”diameter pipe transition coating,Denso Glass Outerwrapwas utilized.

The final result was a good,reliable in-situ coatingrehabilitation system that leavesthe owner company feelingconfident about the healthof their pipeline.

Pictures:

Page 6 - A finished pipeline section.

Left - The effective transition from the new Protal 7250 to the original three-layer polyethylene coating was achieved with a wrap of Denso Hotline Tape.

Above - A final outerwrap of Denso Glass Outerwrap completes the job.

8


The Denso S43/R23 Systemwas again chosen for itsexcellent all round adhesive andCD properties for the protectionof the 450mm diameter pipelinefield joints on this 17km project.

Denso provided full applicationtraining, applicator certification,peel test certification etc,resulting in absolute peace ofmind for the consultant and assetowner alike.

This project was completed ontime and to the satisfaction of allparties concerned.

Starting in July 2009, this was another project within thegreater New Zealand Kupe Oil and Gas field development, forwhich Denso New Zealand has supplied almost all facets ofits long term corrosion protection requirements.

Finished Product PortDelivery Pipeline Protectedwith Denso System Country: New Zealand

Location: Unspecified

Object: Pipeline Joints


Product Densosolution: S43 / R23 System

Project Summary

Product type:Buried Steel Coating

Corrosion Prevention for Pipeline Joints - New Zealand

The pipeline joints are cleaned by grit blasting.

Below: After priming, the S43 Tape is applied to the joint using a Densoman wrapping machine.Below: The R23 Tape is applied over the S43Tape, completing the joint protection system.

9


Corrosion Prevention for Pipleline Joints - Republic of South Africa

There are also three 16” threelayer PE coated lines measuringa total of 180km in andaround Gauteng.

The consulting engineers onthe project are from Arup ,WorleyParsons and Transnet PipelinesThe Joint Venture is called theNMPPP alliance. Spiecapag andthe South African constructioncompany Group Five are themain pipeline contractors onthe project.

Denso South Africa has beenspecified to supply materials forthe field joint coatings on boththe 24” and 16” pipelines.

To date Denso has suppliedthe field joint coating to 150kmof 16” and to 31km of the24” pipeline

The field joint coatingcomprises the Denso Protal

Denso Protects TransnetPipeline’s New Multi ProductPipeline (NMPP) Project

7200 which is then overwrappedwith the Denso Corroklad innerand outerwraps. The field joint isthen protected with the DensoStoneguard 1200.

Bulldog Projects and PipelineCoatings are the liquid field jointapplicators on the project,thefield joint is blasted to SA21⁄2 and

The NMPP Project is designed to efficiently transport diesel,petrol and jet aviation fuel to the inland of South Africa (theGauteng region). It will consist of: A 24” three layer PE coated525 km multi-products liquid fuel pipeline (or ‘trunkline’),including up to nine pump stations, running from Durban,KwaZulu Natal to Jameson Park near Heidelberg in Gauteng.

the Protal 7200 is applied witha roller or applicator pad.

The Corroklad inner andouterwraps are both appliedwith a Densoman Wrappingmachine with 55% overlaps,the Denso Stoneguard 1200 isapplied and secured with anadhesive outerwrap.

The project also required longradius induction heated bendsfor both pipelines ,BulldogProjects and RJ Southey coatedthe bends in their yards. Thebends were blasted and theProtal 7200 spray applied,theCorroklad inner and outerwrapsand Denso Stoneguard 1200is then applied on siteprior to installation.

There were 190 x 24” bendsof various degrees and 96various degree 16” bends.

Country: South Africa

Location: Durban to Heidelberg

Object: Pipeline Joints


Product Protal 7200,Corrokladsolution: Stoneguard 1200

Project Summary

Product type:Buried Steel Coating

A pipeline bend being spray coated with DensoProtal 7200.

Stockpiled pipeline bends, coated with Protal 7200 and ready for installation. The pipeline construction underway.

10


Corrosion prevention for Jetty Piles - United States of America

Over the years theDuluth-Superior Harbor hasexperienced corrosion problemswith many of the dock structuresdue to the bacteria in the water.The environment can be quiteaggressive during the wintermonths as there is a large icebuildup that provides impactdamage, as well as extremethermal expansion andcontraction forces.The SeaShieldSeries 500 and Series 2000FDSystems were used to protectH-piles and cylindrical piles tohelp solve the ongoingcorrosion problem.

SeaShield Series 500The Series 500 was used to

protect the steel H-piles. Thesystem includes a customfabricated Fiber-Form Jacket andSeaShield 550 Epoxy Grout.The Fiber-Forms were fabricatedin two half shells to the shape ofthe existing H-pile to allow fora 1” (25 mm) annulus spacebetween the jacket and pile.The Fiber-Forms were installedand secured with self tappingscrews and temporary nylonstraps. The 1” (25 mm) annulusspace was adjusted with plasticoffset screws. The SeaShield550 resin, hardener andaggregate were mixed and thenpoured through a pneumaticvibratory funnel into the topof the jacket.

SeaShield Series 500 and2000FD Protects Steel Pilesin Icy Environment The Series 500 and Series 2000FD Systems were selected andinstalled in the Duluth-Superior Harbor to provide corrosionprotection of the steel piles.

1.Installation of the two Fiber-Form half shells.

2.Installation of the screws through the tongueand groove closure.

3.Annulus space adjusted with plastic screwsbetween Fiber-Form and H-pile.

4.Pouring of mixed Seshield 550 Epoxy Groutthrough pneumatic vibratory funnel.

Series 500 during winter ice buildup.


11

Corrosion Prevention for Jetty Piles - United States of America

SeaShield Series 2000FDThe Series 2000FD was used

to protect the cylindrical piles.The system includes a DensoMarine Piling Tape and a customengineered HDPE outercover.The Denso Marine Piling Tapewas applied above and belowwater with a 55% overlap.The outercover was theninstalled and secured with 316stainless steel bolts usingDensoʼs proprietary tensioningbars and hydraulic equipment.

The Series 500 and 2000FDSystems have been inspectedafter one year of severe winterice buildup with no damage.The systems have provideda long-term solution for thisaggressive environment.

Denso manufactures a fullline of SeaShield Pile ProtectionSystems and pipeline coatingsthat are considered the choiceby owners, engineers and divecontractors around the world.

Country: United States of America

Location: Superior, Wisconsin

Object: Steel piles


Productsolution: SeaShield Series 500 and 2000 FD

Project Summary

Product type: Sub Sea / Splash Zone Coating

Installation of HDPE jacket and hydraulictensioning system.

Series 2000FD during winter ice buildup.

Completed installation of SeaShield 2000FD on18” diameter pile.

Documents

Volume 29 - Number 1 - Denso 29 - Number 1 ... training, applicator certification, ... Buried Steel Coating Corrosion Prevention for Pipeline Joints - New Zealand