HTLP 60 Wrap-Around Heat Shrinkable Sleeve and Epoxy Installation Guide

Install Guide for HTLP 60 Wrap-Around Sleeve and Epoxy

The most widely used girth weld protection system for three-layer coated pipes.

Notes:
Installation must be done according to local
regulations and usual safety precautions.
This installation instruction is intended for the
Raychem HTLP60 system to be installed on
pipes coated with fusion bonded epoxy
(FBE),coal tar enamel(CTE), 2 or 3 layer PE.

Materials and equipment:

1. Appropriate size HTLP60 sleeve and
WPCP-IV closure, Raychem S1301M
epoxy primer either in small or bulk kits,
with the appropriate epoxy pump, mixing
sticks, Tyco Adhesives approved
applicator pad, protective gloves.
2. Tyco Adhesives recommended torch type
or equivalent.
3. Propane tank with Tyco Adhesives
recommended regulator, hose and gauge.

4. Contact pyrometer
(or Raychem temperature strips).
5. Siliconized hand roller (straight)
6. Raychem calibrated epoxy pumps
(if applicable)
7. Standard safety equipment such as
gloves, goggles, hard hat, etc.
8. For larger jobs epoxy primer can be
supplied in bulk kits.

1. Clean exposed steel and adjacent pipe coating to be covered by HTLP60 sleeve. Remove all contaminants such as oil. Use a solvent that contains no grease or oil type materials.

2. If not factory beveled, chamfer the adjacent pipe coating to an angle of preferably 15°, maximum 30°. Inspect the edge of the existing pipe coating. Disbonded sections have to be trimmed of and the
coating edge has to be beveled again. To avoid possible contamination, it is recommended to use a scraper.

3. Grid blast or sand blast the steel surface to remove loose and foreign materials. The
surface should be cleaned to SIS 055900 -SA 21/2.

4. Grid or sand blast the adjacent pipe
coating over a distance of at least 100 mm
(4"). The total width should be approximately
50 mm (2") larger than the width of the
Raychem supplied HTLP60 sleeve.
Note: prior to blasting, it is recommended to
preheat the exposed steel to 40 - 50° C
(104 - 122°F) to avoid flash rust formation.

5. Wipe the surface to remove dust and
remaining blasting material. Use a clean dry
cloth or air blow.

6. Dose the two component Raychem epoxy. Use pre-dosed Raychem epoxy kits or use Raychem calibrated epoxy pumps. For pre-dosed Raychem epoxy kits, pour content of can B into can A and mix for
approximately 1 minute. Using small epoxy primer kits. Open cans A and B, poor all contents of can B into can A. Stir thoroughly the mixed epoxy for 1 minute. After use follow local regulations for safe disposal Mixed epoxy primer has a pot life of approximately 30 minutes at ambient temperature. As long as the epoxy primer is still liquid, it may be used.

For easy mixing and dispensing, the epoxy primer should be used at a temperature of
min. 18° C (64°F). When necessary, keep the epoxy primer at a heated place or use a
Raychem epoxy heater. Using bulk epoxy primer kits. Bulk epoxy primer should be used at a
minimum of 18°C (64°F), if not keep it in a heated place or use the epoxy primer heater. PRIOR to install the epoxy pump remove the pail lid and stir the epoxy to become a homogeneous mass.
Attach the precalibrated epoxy pump A to drum A, and pump B to drum B. Pump B has a pre-installed spacing ring. The correct mix ratio is obtained with one full stroke of A and one full stroke of B. This will
dispense a mixture that has three parts of A and one part of B by volume. Refer to epoxy installation instructions, additional information is available upon request. After use follow local regulations for
safe disposal.

7. Adjust the torch to a yellow topped blue flame of approximately 500 mm (20") long. Preheat the steel and the adjacent pipe coating to 60° C (140 °F) minimum, 90° C (194°F) maximum. Preheating of the surface
reduces the installation time and ensures proper bonding. Make sure that all necessary items including
mixed epoxy primer are in close proximity before starting preheating. In bad weather conditions, use proper
shielding such as a wind shield in windy conditions or a well ventilated tent in the case of rain.


 

8. Check the preheating temperature with a contact pyrometer or a Raychem recommended temperature indicator strip. Certain temperature markers can cause contamination and therefore their use should be avoided.

9. Immediately after preheating, apply the mixed epoxy primer to the bare steel using a Tyco Adhesives approved application pad. Visually check the surface and ensure all bare steel is covered by the epoxy primer.

10. If not factory cut, cut the corners of the underlaying end of the sleeve to approximately 15 mm x 50 mm (1/2"x2").

11. Immediately after the application of the epoxy primer, and while the epoxy primer is still wet, loosely wrap the HTLP60 sleeve centrally around the welded joint. The edge of the sleeve with the trimmed corners should be on the pipe first. The sleeve should overlap in the 10 to 2 o’clock position and the overlap of the sleeve onto itself should be at least 50 mm (2"). The sleeve should be wrapped around the joint leaving a gap of minimum 25 mm (1") between the bottom of the pipe joint and the sleeve.

12. Gently heat the inside of the overlapping sleeve edge and press down onto the opposite sleeve and with a gloved hand.

13. Heat the inside of the closure patch for 1 - 2 seconds. Position it evenly over the edge of the heat shrinkable sleeve. Press it down firmly. In case of a factory supplied pre-attached closure patch, this step is not necessary. Only heat the patch material and maximum one inch of the heat shrinkable sleeve on both sides of the patch.

14. Start heating the closure patch from one side and slowly move to the other side while pressing down with a gloved hand to ensure good bonding and eliminate air entrapment. During and after the heating, the fabric reinforcement becomes visible as an indication that the closure patch has been heated to the minimum required temperature.

15. For sleeves for pipes of 400 mm (16")
diameter and larger, two installers are
recommended.

16. Begin heating at the center of the sleeve and heat circumferentially around the pipe using a constant paintbrush motion. Continue heating towards one end of the sleeve, followed by the other. In case of strong wind, begin heating the sleeve from one end of the sleeve, opposite to the wind and heat circumferentially around the pipe, using a constant paintbrush motion. The flame should not be held perpendicular to the
sleeve but should be directed towards the shrinking direction.

17. Continue heating towards the other endof the sleeve. Ensure that the total sleeve has been heated evenly and has completely shrunk tightly around the pipe.

18. During shrinkdown, occasionally check adhesive flow with finger. Wrinkles should disappear automatically.

19. Possible air entrapments can be reduced to the maximum by post rolling of the sleeve. Immediately after the sleeve has been shrunk onto the joint area and while the sleeve is still hot and soft, roll the entire sleeve with a segmented roller. Start rolling from the weld bead towards the sides forcing possible air enclosures out of the sleeve. Special attention should be given to the longitudinal and circumferential weld bead, the transition of the mill coating and the patch area. If necessary, areas may be reheated to roll out air.

20. The sleeve is fully recovered when all of
the following have occurred :
1) The sleeve has fully conformed to the
pipe and adjacent coating.
2) There are no cold spots or dimples on
the sleeve surface.
3) Weld bead profile can be seen through
the sleeve.
4) After sleeve is cool, adhesive flow is
evident on both edges.