leaders in corrosion prevention & … · corrosion prevention - buried pipelines denso...

LEADERS IN CORROSION PREVENTION & SEALING TECHNOLOGY

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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

DENSO NORTH AMERICA INC Tel: +1 905 940 825575 Shields Court, Unit 3, Markham, Ontario, L3R 9T4, Fax: +1 905 940 8258Canada Email: [email protected]✓ Anti-corrosion and sealing systems Web site: www.densona.com

18211 Chisholm Trail, Houston, Texas 77060, Tel: +1 281 821 3355United States of America Fax: +1 281 821 0304✓ Anti-corrosion and sealing systems Email: [email protected]

Web site: www.densona.com

DENSO SOUTH AFRICA (PTY) LTD Tel: +27 31 5694319 PO BOX 647, Umhlanga Rocks 4320, Durban, Republic of South Africa Fax: +27 31 5694328✓ Anti-corrosion and sealing systems Email: [email protected]

Web site: www.denso.co.za

DENSO (AUSTRALIA) PTY LTD Tel: +61 399387 1377411 Victoria Street, Brunswick, Victoria 3056, Fax: +61 399387 6973Australia Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

DENSO (NEW ZEALAND) LTD Tel: +64 9262 24791/5 Joval Place, Manakau City, Auckland, Fax: +64 9262 2494New Zealand 1701 Email: [email protected]✓ Anti-corrosion and sealing systems Website: www.densoaustralia.com.au

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


18211 Chisholm Trail, Houston, Texas 77060, Tel: +1 281 821 3355United States of America Fax: +1 281 821 0304

Email: [email protected] site: www.densona.com

411 Victoria Street, Brunswick, Victoria 3056, Tel: +67 399387 1377Australia Fax: +67 399387 6973

Email: [email protected]: www.densoaustralia.com.au

1/5 Joval Place, Manakau City, Auckland, Tel: +64 9262 2479New Zealand 1701 Fax: +64 9262 2494

Email: [email protected]: www.densoaustralia.com.au

Welcome to another collection of recent application stories featuring Denso products.For further information please contact your local Denso company listed below or fax/mail

the form on the back page of this brochure.

New Pipeline gets DensoProtection

Petronet, South Africa’s largest fuel pipeline operator, specified theDenso Ultraflex/MDP Tape Wrapping System for the corrosionprevention of a new 33km 324mm OD pipeline.

The route covers sometreacherous terrain requiring thepipe to be strung out, weldedand snaked into the trench.

The wrapping takes place afterthe butt welds have ben x-rayed.The surface is prepared to a St2standard with mechanical cupbrushes. The pipe is then primedwith the fast drying DensoPrimer D prior to the innerUltraflex and outer MDP tapesbeing applied by a DensoWrapping Machine.

The spec calls for a 55%overlap or double wrap of bothinnerwrap and outerwrap.As a result of this, a total of74,000m2 of tape has beenordered.

MDP Rockshield outerwrapsare manufactured on DensoSouth Africa’s new IndustrialTape Plant to the ISO 9002manufacturing standard.

The work is being carried outby Protekon Construction withthe contract period being oneyear.

Corrosion Prevention - Buried Pipelines

Above: The Denso system is applied prior to the pipe being ‘snaked’ into the trench.

Below: 12m lengths of pipe stockpiled ready for welding into position.

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South Africa

To enable quick identification of the subjectmatter within each story in this brochure we

have adopted the following colour codes.

PROJECTS INVOLVING:

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.....

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Canada

Cold climate conditions cangreatly influence the methodsused in new pipe constructionand in the maintenance ofexisting pipelines. In particular,cold climate conditions canaffect the storage, handling,application and backfill readinessof many field applied coatingsystems. As well, the long-termcorrosion protectionperformance of some types ofcoatings can benegatively affected by coldclimate conditions.

The maintenance orreplacement of coatings onexisting in-service, operating pipelines in cold climateconditions can pose quite achallenge. In this case, the

substrate temperatures can noteffectively be altered to aid incoating cure times, as theproducts flowing in the pipetend to act as a huge heat sink.Coating products have to behandled and applied with thesetemperature influences beingtaken into consideration. Oftenthis requires the coatings to bekept warm during the storage,handling and applicationprocesses and may also requirethe work area to be temporarilycovered over and heated duringthese activities.

Various other pipelineconditions exist that can affectcoating performance in coldclimate conditions:

Denso Protal 7125 has been specially developed as a two-part liquid pipeline coating to be applied in colder climate conditions. Sincethe introduction of Protal 7125 over three years ago, it has becomethe pipeline coating of choice in colder weather conditions and oncolder in-service operating pipelines.

● Environment of exposure e.g.chemicals, solvents.

● Availability of surface preparation equipment and heating equipment.

● Ambient conditions at time of coating application.

● Condition and compatibility of any existing coatings.

● Terrain and backfill material (rocky, sandy, clay, etc.).

● Skills of the work crew available.

● Intended life expectancy of pipeline.

● Site conditions, such as degreeof surface cleanliness and dust contamination, product shelf life, product pot life and cure temperature range (if applicable).

● Significant pipe movements due to temperature fluctuations and heavy soil stress conditions (dry-wet clay).

Field applied coatings on newpipeline construction are the leastaffected by cold ambientconditions. In this case, thesubstrate temperature can bequickly raised to meet theapplication requirements byapplying external heat, atechnique not possible on anoperating pipeline.

The true challenge in coldclimate conditions is in themaintenance and repair or replacement of coatings onexisting in-service, operatingpipelines. This is where Protal7125 excels. The ease ofapplication, fast cure and quickbackfill times make Protal 7125well liked by field crewsapplying the product.

Denso Protal 7125


Protal 7125 applied to a 273.1mm (10”) operating products pipeline at 5°C (41°F) that was cured and ready to bebackfilled in 65 minutes.

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Canada

Protal 7125 has been extensivelytested in numerous coatingtesting laboratories withexcellent results.

Protal 7125 Features:

● Cold temperature application and cure (down to -20°C{-4°F}).

● Will not freeze.

● Fast cure and initial set.

● High build (in one coat).

● Brush, Roller or Spray application.

● Packaged in 1.0 litre kits and repair cartridge packs.

● Excellent adhesion to steel and FBE.

● High abrasion resistance.

● Does not shield cathodic protection.

● Winter grade or summer grade available.

● High resistance to moisture during cure.

The combinations of easyapplication with good laboratorytest performance have madeProtal 7125 the cold climatecoating of choice in Canada.


Above: Pipe coated with Protal 7125 that has been applied by roller. Protal 7125 Repair Cartridge being dispensed prior to mixing for brush application.

Below: Protal 7125 is applied by brush at pipe support areas that were left during roller application.

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The Netherlands

Denso Protection for OffshoreCranes

Kenz Crane B.V. at Zaandam in the Netherlands produces liftingequipment for the offshore industry and is one of the five largestcompanies in this field, in the world.

These cranes, used on drillingrigs and supply boats, arehydraulically driven and have toendure severe maritimeenvironments with temperaturessometimes exceeding 50°C.Consequently, attention must bepaid to corrosion which canoccur rapidly in theseconditions.

For maintenance purposes thehydraulic mains need to bedisconnected frequently/easilyand the couplings areparticularly vulnerable tocorrosion.After due consideration, Densyl

Tape was chosen for its superiorperformance in hightemperatures against moistureand salt.

The Multi Purpose SupportVessel ‘Toisa Polaris’ with itscrane (capacity of 250 tons at aradius of 13m reaching to adepth of 1200m) has since beenprotected by Densyl Tape in thismanner.

The detail of the applicationcan be seen quite clearly in thephotograph depicting a similarapplication to a crane on theMobil Mallory Gasplatform inthe North Sea.

Corrosion Prevention - Exposed Offshore Cranes

This application of DensylTape has worked perfectlyshowing once again, yet anotherapplication for a proven, reliableproduct.

Above: Densyl Tape applied to a crane’s hydraulic connectors on the Mobil Mallory Gasplatform.

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United States of America

The pile repair system chosenwas a concrete encapsulationwith fiberglass forms. The consultant, Han-Padron and NewYork City EconomicDevelopment Corporation

Pile Rehabilitation in theBig Apple

approved Denso’s SeaShieldFiber-Forms.

The SeaShield Fiber-Forms(fiberglass jackets) are a customfabricated fiberglass jacket with a tongue-and-grooveclosure. It provides a strong rigidform to allow concrete to bepumped into the annulus spacebetween the jacket and timberpile.

The timber piles that hadreceived extensive damage fromthe marine borers received concrete encapsulation. Therepair involved building areinforcement cage around the piles and then installing theSeaShield Fiber-Form. Theconcrete was then pumped into the annulus space, whichincreased the overall strength ofthe pile. To provide ease of application the forms werefabricated in a translucent colorto allow the contractor to view the concrete level duringthe pumping operation.

The contractor, Bob Bueckerof Strongwork Diving stated“The SeaShield Fiber-Forms were of high quality, providedon-time delivery and easy toinstall due to the jackets being translucent”. The engineersand owners were pleased withthe installation as the applicationwas completed ahead ofschedule.

Pier 16 in Manhattan, NY is one the city’s most active tourist pier. Itis adjacent to the Fulton Fish Market. In service for over 50 years,the timber piles have received marine borer damage, whichthreatened the structural integrity of the pier. This major rehabilitation called for more than 6,000 LF of timber pile repairs.

Corrosion Prevention - Jetty Piles / Splash Zone

Above: Concrete is pumped into the annulus spacebetween the jacket and timber pile.

Above: The SeaShield Fiber Forms are positioned around the timber piles.Below: Completed SeaShield Fiber-Form system.

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United Kingdom

Denso Long-term Protection Withoutthe Need for Abrasive Blasting

Corrosion Prevention - Exposed Steel Pipebridges

Severn Trent Water has carried out a renovation programme onseven pipebridges carrying treated water in Warwickshire. To givelong-term protection and minimise costly future refurbishment, thecontractors, D & D Industrial Coatings Ltd of Warrington, Cheshire,have selected a Denso Steelcoat tape wrap system for the exposedpipeline and a Denso Steelcoat Epoxy Mastic liquid coating forprotecteing adjacent steelwork forming the pipebridge.

Renovation of the finalpipebridge, Berkswell south ofCoventry, which carries two24in water pipelines over the

main London to Birminghamrailway line is now fullycompleted.

Surface cleaning preparations


Denso Protection at London’sNew Exhibition Centre

Around 1km of 600mm diameter ductile iron and steel pipeworkand fittings supplying water for the Excell Exhibition Centre inLondon’s Royal Victoria Docks area has been protected with a DensoTape System.

Subcontractors DOCWRAapplied Denso Primer followedby Densoclad 70 Tape. Forcouplings and fittings, DensoProfiling Mastic was used tosmooth the profile of the jointsbefore applying the Densoclad70 Tape.

Densoclad Tapes consist of athick polymer bitumen adhesivelaminated to a tough plasticisedpvc backing. These cold applied

tapes are designed for protectingburied or immersed pipes andfittings.

The Excel Exhibition Centre isdesigned to replace Earls Courtand Olympia as London’s majorexhibition venue, with theadvantage of easier access byroad, the Docklands LightRailway and the adjacent CityAirport. It was built by maincontractor Sir Robert McAlpine

for English Heritage. The siteincludes a Grade II listedVictorian warehouse.

The completed Denso Steelcoat Systems on the Ragley Hall pipebridge.

Denso Profiling Mastic was used to smooth the profileof the couplings prior to wrapping withDensoclad 70 Tape

were carried out by hand powertool methods. Denso Steelcoat400/100 tape wrap systemprovides a controlled coatingthickness and was easily and veryquickly applied to all main pipesections and flanges

A final Denso Urethane Topcoatwas selected in preference toDenso Acrylic Topcoat due to lowtemperature conditions during thecoating application. DensoSteelcoat 700 brush appliedsystem for the steelworkcomprised two coats of DensoS.T. Epoxy Mastic followed byDenso Weathershield Urethane.

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United Kingdom

Linings - Water Storage Tanks


Archco-Rigidon Lining Protects‘Earthquake’ Water Tank

As part of a periodic safety review by British Energy it was decidedto build a new seismically qualified standby water storage tank attheir Teesside-Hartlepool Power Station. With a capacity of morethan 1600m3, its purpose is to help cool the reactor in the unlikelyevent of an earthquake in the area.

An earlier water storage tankhad been coated with a coal tarbased paint but after six yearsBritish Energy maintenanceengineers found it “less thandesirable”. Following research ona number of available linings,they chose Archco-Rigidon423D. Formulated from a glassflake filled vinyl ester resin, ithas been specially developed togive long life protection incorrosive environments.

The main contractors for thedesign of the new storage tankand the cooling system wereThermal EngineeringInternational. Sub-contractors

McDonalds Engineering built theTank and applied theArchco-Rigidon 423D lining.

The Pipelengths being wrapped with Densoclad 70 Tape.

Internal view of the water tank lined withArchco-Rigidon 423D.

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Australia

The facility is designed tostore and process oils ready forexport. A final part of the projectis to construct and install 1.6kilometres of 153mm Ø pipefrom the plant at Kargoil for thetransportation of Linseed Oil tothe facility at the bulk liquidberth.

Selecting a coating for the oilline was subject to numerousconditions including the abilityto withstand temperatures of upto 65°C and proven performance

Denso Ultraflex 1500 -Not just a girth weld coating!

Recently in the city of Newcastle (located 150km north of Sydney inNew South Wales), the Craig Mostyn Group completed a newfacility at Kooragang Island’s bulk liquid berth.


in aggressive soil conditions. Inaddition long term, cost effectivecorrosion prevention wasrequired as well as ease ofapplication on site.

Denso Ultraflex 1500 wasselected not only for the girthwelds, but also as the fulllinepipe coating. The contractorhas applied the tape using ahand-wrapping machine on site,to ensure the correct overlapsand tension.

The finished Denso Ultraflex 1500 Tape application demonstrating its excellent linepipe wrapping properties.

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