A carbon steel pipeline at a water irrigation Plant, 31 metres (101.7 ft) in length with a diameter of 1.5 metres (4.9 ft), was exhibiting severe corrosion. This had resulted in a significant loss in the original wall thickness of the pipeline. In turn, this meant that the structural integrity of the pipeline was compromised and, therefore, the problem needed to be promptly rectified. The Customer required a solution that would not only repair the corroded pipeline, but also protect it against future corrosion damage for the long term.
Performing a repair inside the pipelines presented a considerable logistical challenge. The traditional method is to weld metal sheets onto the damaged areas. However, oftentimes difficulties will arise in terms of the practicalities of handling and positioning large replacement sheets inside pipelines. Furthermore, welding the metal sheets onto the aged metal substrate can make the pipelines susceptible to further defects, distortions and corrosion. The hot work required within this process also comes with inherent health and safety risks.
Polymeric Pipe Repair Solution Specified
Following an inspection from BS Italia, Belzona authorised Distributor for Italy, in collaboration with the contracting Company, a combination of polymeric technology was specified.
The 2-part epoxy paste, Belzona 1121 (Super XL-Metal), was chosen to create a smooth profile prior to the application of the pipe wrap system, Belzona SuperWrap II. This pipe repair system is specially designed to facilitate the fast and simple, in-situ repair of through- and thin-wall defects on pipes and tank walls. To consolidate the repair and protect the substrate against future damage, the high-performance coating, Belzona 5821, was specified. This system is specially designed for operation under immersion, making it the perfect solution for the highly aqueous application area.
Before fully committing to this application, tailor-made mock-ups were created in order to demonstrate the performance capabilities of the Belzona SuperWrap II pipe repair system. Thoroughly satisfied with the mock-ups, the Customer opted for the complete polymeric solution.
Application Method:
After appropriate preparation of the surfaces was conducted via abrasive blasting the internal profiles were reconstructed with Belzona 1121 (Super XL-Metal). Next, the Belzona SuperWrap II system was applied. Firstly, the Belzona 9381 reinforcement sheet was measured out and then wetted out with the Belzona resin system, Belzona 1981. The resin was further applied to the application area before the reinforcement sheet was applied on top until the original design thickness was achieved. Belzona SuperWrap II was overcoated with Belzona 5821 to provide enhanced abrasion and erosion resistance.
Polymeric Technology Mitigates Need for Hot Work
“By choosing polymeric technology for the repair solution, this successfully mitigated the need for hot work thanks to the cold-curing properties of these systems. As these systems were applied in-situ without the need to manoeuvre large metal sheets into the pipelines, this further removed any logistical complexity. In addition, as these systems are designed with fast-curing properties, this ensured that downtime was kept to an absolute minimum.”
About BS Italia:
BS Italia was founded in 2005 from the collaboration between Carco S.p.a. and Nuova Tecnomarine Srl. Based in La Spezia, BS Italia has over 40 years of experience in repair and maintenance and the use of Belzona polymeric technology. The authorised Belzona Distributorship provides a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries in Italy including: marine, petrochemical, oil and gas, renewables, amongst others.
Want to Learn More About BS Italia?
Chloe Hirst, Senior Copywriter, Belzona Inc., Harrogate, UK.
LinkedIn: https://www.linkedin.com/in/chloe-hirst-2b1a79211/
