volume 28 - number 3 - denso...

LEADERS IN CORROSION PREVENTION & SEALING TECHNOLOGY

Volume 28 - Number 3

Densoclad Tape protecting pipes in a corrosive brine field environment - see story page 4.

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


SEASHIELD INTERNATIONAL Tel: +1 281 821 3355✓ Marine corrosion protection systems Fax: +1 281 821 03049747 Whithorn Drive, Houston, Texas 77095 Email: [email protected] States of America Web site: www.densona.com

SEASHIELD INTERNATIONAL Tel: +61 1300 658 590✓ Marine corrosion protection systems Fax: +61 1300 655 064411-413 Victoria Street, Brunswick, Victoria 3056, Email: [email protected] Website: www.densoaustralia.com.au

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

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

Corrosion Prevention for Historic Crane - United Kingdom


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Country: United Kingdom

Location: Llechwedd Exchange Sidings, Wales

Object: Crane pillar

Problem: Corrosion prevention

Productsolution: Denso Paste and Denso Tape

Project Summary

Product type: Buried Steelwork Coatings

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.....

Denso Protection forHistoric Welsh CraneA key feature of the Llechwedd Exchange Sidings industrialarcheological site on the A470 Improvement Scheme nearBlaenau Ffestiniog in Wales, is a crane that first saw servicein the late 1800s loading slate from the nearby quarries onto railway trucks. The site which has been designated as‘An Area of Special Archeological Importance’ has been thesubject of a design and build scheme, with Giffords beingthe designer for the original contractors, Alfred McAlpine,who are now part of Carillion plc.

Giffords designed a foundationfor the original pillar of theLlechwedd crane to go in its newlocation. The pillar is the original500mm diameter casting,which has been protected fromcorrosion by an application ofDenso Paste followed byDenso Tape before beingsunk 2.5 metres into the ground.Denso Tape is a non-wovensynthetic fibre fabric impregnatedand coated with an adhesivecompound based on petrolatum.

In its former days the cranewould load the slate that camedown from the quarries on

narrow gauge quarry wagonsto standard gauge rail wagons.Those going north to Llandudnowould go through a 11⁄2 mile long

tunnel, which was then thelongest in Britain, whilst anotherrail line would take the slatedown to Portmadog.

The original crane pillar is coated with Denso Paste before being wrapped with Denso Tape. The protected crane in its final position.

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Corrosion Prevention for Buried Pipeline - United Kingdom

Densoclad 70S Tape Chosenfor Major 23km PipeWrapping Contract Densoclad 70 and 70S Tapes were chosen for the completeprotection of some 23km of pipeline lengths in a majorwrapping contract recently completed by Barrier Ltd atWallsend, Tyne and Wear. The pipeline lengths rangingin diameter from 50mm to 500mm, have been wrappedfor a project in the Cheshire brine fields.

The large diameter pipes werewrapped on a motorised rollingrig specifically designed for fastthroughput with Densoclad 70STape using rolls of 225mm widex 60m long. Densoclad 70S wasused here because it had astiffer pvc backing to enable itto withstand the greater tensionexerted by the motorisedrolling rig.

The 50mm diameter pipeswere also wrapped on amotorised rolling rig butDensoclad 70, 100mm x 60mwas used here. Barrier reportedthat their customer deliverytargets were not only matchedbut exceeded for each pipe size.

Densoclad 70S heavy dutytape is designed for corrosionprevention of large diameterpipes, welded joints, bends andfittings. The extremely tough pvcbacking combined with polymerbitumen adhesive ensurecomplete protection andexceptional resistance to impactby poor backfill or aggressiveground conditions.


Location: The Cheshire brine fields

Object: Pipe lengths


Productsolution: Densoclad 70S and 70 Tape

Project Summary

Product type: Buried Pipeline Coatings

Photos:

Top: Rolling rig application of Densoclad 70S Tape to pipeline lengths at Barrierʼs premisesin Wallsend.

Middle & bottom: Wrapped pipeline lengths in the Cheshire brine fields.


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Corrosion Prevention for Steel Vessel Interiors - United Kingdom

Archco-Rigidon ProtectsOil Production WaterFilter SystemForsythe Ltd of Rothes, Moray, N.E. Scotland, recentlycompleted the fabrication of five vessels which make upa water disposal media filter system destined for oilproduction in Azerbaijan.


Location: Moray, N.E. Scotland / destination Azerbaijan

Object: Steel vessels

Problem: Internal corrosion prevention

Productsolution: Archco-Rigidon 403D

Project Summary

Product type: Industrial Tank Linings

In order to give maximuminternal corrosion protection thevessels were first shot blastedand then given a spray applicationof Archco-Rigidon 403D vinylester glass filled coating. Thetwo largest of the five vessels

internally coated have acapacity of 268 cubic metres.

The work was carried outby Forblast who areForsythe’s specialist coatingsubsidiary company.

The contract was placed with

Photos:

Top: Spray application of Archco-Rigidon 403D.

Left: One of the five vessels.

Above: Internal shot of the vessel showing the completed lining.

Forsythe and Forblast by PetrecoLtd of Rugby, who were workingdirectly for the AzerbaijanInternational OperatingCompanies (AOIC). Membercompanies of AOIC include BP,Statoil and ExxonMobil, amongothers. Once installed inAzerbaijan the ‘Produced WaterDisposal Media Filter System’will allow significant increase inthe production of oil.

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Coatings Application Certification Process - Canada

If a coating is not appliedproperly by the applicator, it is in some instances better notto apply a coating at all.Unfortunately when a coating failsthe first to take blame is thecoating itself, although most of thetime the problem is actuallycaused by the improper methodof application or incorrect surface

preparation. This is a globalproblem without a simple solution.

In Canada, Denso worksclosely with industry to try andensure people are educated onthe proper installation practices for all of our coating lines; thisincludes working with personnelfrom engineering firms, ownercompanies, contractors andcoating specification writersand inspectors.

Although we are very attentiveto all the Denso products, ourliquid coatings require the highestlevel of diligence from anapplicator/contractorstandpoint due to the necessityfor more detailed proceduresfor surface preparationand application. One of the controls we have putinto place to try to ensure thatour products are being appliedproperly is by conductingcertification/training programsand issuing certificates to theapproved contractor for bothfield/ hand applied and sprayapplied coatings.

Denso CanadaCoatings ApplicationCertification ProcessOne of the biggest challenges facing the coatingindustry today is ensuring that the proper application techniques are being performed to the correct specifications and manufacturers’ guidelines during the entire coating application period.

Field Certification (Handapplication)

One area requiring certificationfor application of Denso liquidcoatings is in the hand applied(brushes, rollers, trowels)application to girth welds orwelded joints of pipe in a newpipeline installation.This tasktakes place in the pipeline rightof way and will see a wide rangeof variables that challenge thetask of proper installation - frominexperienced coating crews toextreme weather conditions.

These conditions requireconscientious attention if thecoating is to be applied properly.

One must remember thatsome of these projects havetens of thousands of jointsand contractor negligencecan contribute to catastrophicfailures even if only a fewjoints are poorly completed.

The certification process iscompleted by a recognizedDenso representative observingthe actual application processin the field and taking thenecessary measurements for

Above and below: Denso certification cards are issued for handapplied applications that are considered of an acceptable standard.


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Coatings Application Certification Process - Canada

inspection is also done,including observations ofequipment maintenance, areview of the shop QA/QCpolicy, pipe capacity andhandling capabilities, shopcleanliness, etc. The certificationgranted in this instance isreviewed regularly andre-approval takes place whenthere is a change of ownershipor there is a time period greaterthan two years between theapplications of Denso products.

An example of a Denso spray application certificate.

surface profile, dew point, pipetemperature, wet film thickness(WFT), dry film thickness(DFT), hardness, etc.

This observation may includesome destructive testing also.Once the process has beencompleted satisfactorily and thecontractor has shown properdiligence, certification cards areissued to the crew. This is aprocess that usually takes placeat the start of a project and mayneed to be repeated dependingon the duration of the project. These certification cards aremade out to the individualsand are valid for one year.

Spray ApplicationCertification

The spray certificationprocess is different in the sensethat when granted it givescertification to a company,usually a shop coating facilitywhich may also provide fieldapplied spray services. Themarket is such in Canada thatspray application representsopportunities for coating ofunderground or submergedpiping and the internal liningsof tanks with Denso liquids.

The certification process isa more involved procedure froma Denso standpoint, where allmeasurements taken in the fieldapplied/hand certification arerepeated in the coatingsapplication shop and, an actualspray out with the Densospray-grade coating is observedon a pipe sample. This sampleis then sent to a coatingsevaluation lab for testing.These independent, thirdparty tests include adhesion,cathodic disbondment andmore thorough DFT setof measurements.

A systematic facility

Conclusion Denso Canada has offered

this no charge service to ourclients for many years now.It goes without saying that theapplication process is muchbetter served in all cases witha competent, full time NACECertified Coatings Inspectoron-site who is involved for the length of the project.

For Denso, as a coatingsmanufacturer, thesecertifications are a constantwork in progress due tolabour turnover and changesin the market place and it is atopic that we take very seriouslyin Canada. Owner companiesare very receptive to this QCmechanism and view it asgood customer service andvalue added to the product.

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Corrosion Prevention of Pipeline Girth Welds - United States of America

The Protal 7125 is a fast cure,low temperature liquid coating that can be applied in temperaturesdown to -4°F (-20°C). This allowedthe coating crews to proceedwithout delays of preheating and

no down-time due to cold weather.The girth welds were prepared toSSPC-SP 10/NACE No. 2. Thecoating was spread out by brushtaking approximately 5-8 minutesto complete each joint.

Kinder Morgan RockiesExpress Pipeline (REX)uses Denso Protal 7125New pipeline coating applications in the Midwest andNortheast USA can be very challenging during the coldweather months with temperatures below freezing. Protal 7125 was chosen as the girth weld coating for thewinter months on the Kinder Morgan Rockies ExpressPipeline (REX) Project. Once completed the REX Pipeline willbe 1,679 miles of 42” diameter pipeline. It will be the largestcontinuous gas pipeline ever built in the United Statesand will extend from Colorado to New Jersey.

Mixing of Protal 7125.

Completed section of the Kinder Morgan REX Pipeline

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Corrosion Prevention of Pipeline Girth Welds - United States of America

On directional drill joints the coating was applied at 50 mils in one coat and on the main line girth welds the coating was applied at 25-30mils in one coat. Protal 7125 isalso being used for tie-ins andpatching of the damagedFBE main line coating.

The project will continuethrough the summer of 2009 inwhich our Protal 7200 will beused on many of the remaininggirth welds during the warmermonths. The versatility of ourline of Protal Liquid Coatingshas provided Kinder Morganand the contractors theadvantage of dealing withsevere temperature rangeswith no project delays.

Denso manufactures a fullline of Protal Liquid Coatingsthat are considered the choiceby owners, oil and gasengineers and contractorsacross North America.

Country: United States of America

Location: Midwest USA

Object: Coating of buried 42” natural gas pipeline girth welds


Productsolution: Denso Protal 7125

Project Summary


Above: Applying Protal 7125 at 50 mils for directional drill on 42” diameter pipe.Below: Coated girth weld with Protal 7125

Applying Protal 7125 by brush.

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Corrosion Prevention of Gas Pipeline - Republic of South Africa

RPN Pipelines installed thepipeline and Isotec were thecontractors who applied thetape with our Densomanwrapping machines.

DENSO S43/R23 PROTECTSSASOL GAS LINEDenso South Africa supplied Sasol Gas with the Denso ButylS43/R23 System for the protection of 2km of 6” pipeline.

Country: South Africa

Location: Gauteng Province

Object: Gas pipeline


Product Denso Butylsolution: S43/R23 System

Project Summary


In total 2500 sq.m. of the innerand outer wrap were supplied.The job was completed in timeto the satisfaction of the client.

The 6” gas pipeline protected by the Denso Butyl S43/R23 System.


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Resistant Lining for Concrete Bund - Australia

Country: Australia

Location: Sydney, New South Wales

Object: Concrete bund in desalination plant

Problem: Resistance to chemicals and acids

Productsolution: Archco-Rigidon 701ESR

Project Summary

Product type: Industrial Bund Linings

Archco Rigidon 701ESR, andepoxy novolac resin glass fibrematt laminate was selected forthe work due to its excellentperformance in trials whenimmersed in 98% sulphuricacid and previous successfulcase histories.

A local contractor, Epteccarried out the work with ambienttemperatures of 15°C to 28°Cduring application. The concrete

Archco-Rigidon Protects Concrete AcidBund AreaA concrete bund on the newdesalination plant in Sydney,New South Wales has hadArchco-Rigidon 701ESRspecified and applied toprotect it from spillages ofvarious aggressive chemicalssuch as solutions of Ferricsulphate (up to 40%), sodiumhypochlorite, sodiumbisulphate and fluorosilicicacid amongst others. The Phranged from 2 to 4 duringoperations. The groundunderneath the bund isreclaimed compacted clay asthe plant was built on swampland south of Sydney.

substrate moisture content wasnever below 9% due to theswamp area. The substratewas prepared by wet abrasiveblasting before application of 2coats of epoxy primer in attemptto rectify concrete porosity. The701ESR was trowel and rollerapplied to an overall nominal drythickness of 3mm.

Left: The bund during the application of theArchco-Rigidon 701ESR lining.

Above: The complete 3mm thick application.

For further information - tick boxes, fill in coupon and fax or post to your nearest Denso branch(full list of addresses on page 2).

Name: Title:

Company:

Address:

Phone: Fax:

We also offer tried and tested systems to deal with all the problem areas listed

below, simply fax back this completedpage and we will supply you with

more information.

BURIED ONSHORE COATINGS

External corrosion prevention for underground pipelines, welded joints, valves and fittings.

Protection of mounded LPG vessels and fuel tanks.

MEMBRANES & FLASHINGS

Tanking / waterproofing.

Exposed rooftops and parapets.

SEALING MASTICS

Joint sealing of precast concrete

manholes and culverts.

Joint and crack sealing of asphalt road surface wearing courses.

Joint sealing for airport runways.

Sealing of cable entry ducts.

EXPOSED SURFACE COATINGS

Corrosion prevention for chemical plant, structural steelwork, above ground pipes, storage tanks, offshore rigs, bridges and support cables, cranes and pipe bridges.

Corrosion prevention for metal roof purlins and metal roof sheets.

Protecting pre-stressing and post tensioning bridge cables and ground anchorages.

Would you like more information about our long-term corrosion prevention

and sealing systems?

SUB SEA/SPLASH ZONE COATINGS

Maintenance corrosion

protection for steel jetty piles.

Subsea pipelines and outfalls.

Protection of timber and concrete piling.

If you are interested in any of the productsfeatured in this issue of the Denso Digestplease tick box:

Please indicate page number(s):

FAX NUMBERS UK: +44 (0) 20 8761 2456 ● USA: +1 281 821 0304 ● CANADA: +1 416 291 0898

AUSTRALIA: +61 1300 655 064 ● NEW ZEALAND: +64 9274 1258 ● SOUTH AFRICA: +27 31 569 4328

INDUSTRIAL LININGS

Internal linings for tanks,

pumps, vessels and pipelines.

Linings for concrete bunds

and floors.

External abrasive wear protection

INDUSTRIAL TAPES

Sealing and insulating

Protecting and bonding

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DIY WEATHERPROOFING

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261.4.2009 Vol 28 No.3 Quarterly Publication

WINN & COALES INTERNATIONAL LTDDENSO HOUSE, CHAPEL ROAD, LONDON SE27 0TRTEL: +44 (0) 20 8670 7511 FAX: +44 (0) 20 8761 2456EMAIL: [email protected] WEB SITE: www.denso.net

Most Denso products are covered by patents and the words “DENSO”, “DENSYL”, “ARCHCO-RIGIDON”, “DENSOPOL”, ”DENSOCLAD”,“TOKSTRIP”, “CORROCLAD”, ”SYLGLAS”, and “PROTAL” are registered trade names in the UK and many other countries.

Certificate No. FM 01548BS EN ISO 9001:2000

volume 28 - number 3 - denso...

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