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TRANSCRIPT
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Ms. Susanna Giovannini President & CEO
IBIX Srl
(Tecno Supply Division)
AMI Field Joint Coating Conference London 26-27 September 2017
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• 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
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• 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
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Wet & Dry Air abrasion systems
Spotblasting
Portable blasting 3 lt – 60 lt capacity
(0.8 to 15.85 gal)
Automation 4
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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
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In Flame Spray Equipment and Thermoplastic Coating Powders since 1997
Automatic thermoplastic coating equipment
First manufacturer designing automated flame spraying
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- 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)
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• 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
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Oil & Gas Coatings & Technologies must deliver:
• Performance – maintaining the key coating properties: ! Adhesion ! Integrity ! Flexibility
• Reliability • Consistency • Controllability • Repeatability
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• 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
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• 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.)
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• 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
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• 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.
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• 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
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• 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 $$$$$$$ ?
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• 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
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• 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
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• 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.
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• Ideal for 3LPP, 3LPE, coating of bends, buckle
arrestors and custom fittings.
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• 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
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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
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• 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
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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%
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• 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
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Spray Pattern
• Old Equipment • Modern Flame Spray
Low volume in round pattern
High volume in elliptical pattern (normal paint spraying)
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• 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
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• 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
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Blasting + Induction Heating (Clam Shell
System)
Fusion Bonded Epoxy spraying (Automatic)
Tie Layer (simultaneous
spraying FBE + PP/PE)
PP/PE Top Coat Water Quench
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• 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
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• 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
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• 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
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• 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
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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.
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Field Joints
Buckle Arrestors
Bends
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Objectives & Benefits
Eliminates the “human”
factor
Consistency and
repeatability
Health & Safety
Homogeneous coating
Speed
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• 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
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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.
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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].
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• 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
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• 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
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• 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
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• 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
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Electric Cabinet and PLC
3 + 3 sets of guns fixed on 2 opposite arms Transverse and 180° rotation movement of the arms
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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
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Spraying parameters: • Spray pattern with medium size guns (7 cm / 2.7 inch approx.) • Spraying speed (adjustable) • Spraying time (adjustable) • Spraying deposition rate (adjustable)
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• 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
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On-board 4 x digital pyrometers for temperature monitoring
Hand-hold infrared digital pyrometer double checking the current temperature
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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
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• 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 53
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• 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
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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
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