DIRAX Road Bore Coating

DIRAX Directional Drilling Pipe Coating

     In the world of pipeline coatings, no application is more demanding on a coating than road bores, bundled road bores and directional drills.  The sheer force involved with dragging one or more pipelines through a bored out hole that might stretch for thousands of feet is incredible.  Sure, different types of mud are often used to bring lubrication into the picture, but gravity is still going to be pulling that pipe down to drag on the lower end of the bore hole.  There are still going to be potential rocks, tree roots, gravel and other debris that could possibly crash into that pipeline.  These are dangerous applications that will certainly impact the life of your pipeline.

    

     DIRAX is a multi layer coating system.  The first layer and the primary corrosion coating on the bare steel of your field joint is a two part, curing epoxy (S1301M).  The second layer brings a high shear copolymer adhesive.  The third and outermost layer is a radiation crosslinked high density polyolefin backing with a layer of a fiber mesh woven into the inside of it.  Then; at the front end; you do it all again with the wear cone which will be installed 1/2 on the leading edge of the DIRAX sleeve and half on the factory applied pipe surface.  On the front end; this is a 9 layer pipe coating all working together cohesively to keep anything from getting close to your pipe surface.

• DIRAX is highly resistant to shear and peel forces induced by soil and thermal movements.  DIRAX is tough.
• DIRAX offers abrasion and wear resistance at pull through comparable to mill applied coatings.  DIRAX creates a monolithic coating system for your field joints.
• The wear cone protects the leading edge of the sleeve against pull through forces and provides additional strength and security; increasing reliability.
• DIRAX sleeve is applied over wet epoxy.  There are no curing or waiting times before the strong mechanical and chemical bonds are formed.  Application is very fast; saving a lot of man hours. 
• Superior cathodic disbondment and hot water immersion resistance offers the optimum barrier against corrosion.
• Pre-attached closure strip allows fast, easy and repeatable application.
• Low preheat requirements mean faster installation time.

      As you see here; the DIRAX backing is supplied at 1.85mm and would shrink all the way down (if allowed) to reach a thickness of 2.3mm.  The adhesive is supplied at 1.2mm and gets thicker during installation.  Add the leader strip thickness and at the front edge of the DIRAX coating system you could have a coating more than 6mm thick!

Just a few of the data points for the DIRAX coating system

Casing Seal

Sealing A Casing Pipe

     When working with casing pipe; making sure that no water (or other foreign substances) gets into the casing and begins to rust it out from the inside is absolutely imperative (not to mention the fact that DOT regulations do generally require that casing pipes be properly sealed by approved methods). 

     This is something we deal with all of the time.  There are actually two options for sealing up casing pipe.  Because the costs of these options are so low; I've actually seen many cases where both are installed (they can be installed simply and easily without obstructing one another).  These two options are LinkSeal and Caseal.

     Linkseal is actually a ring around the pipe that fits inside the casing pipe; surrounding the carrier pipe.  It forms a physical seal and is able to hold internal pressure.  This is done by linking together multiple links to form an air and water tight seal around that carrier....sealed up to the internal surface of that casing, creating a perfect water and air tight seal.  Of course, there are occasions where physical damage or some kind of installer error could allow some sort of a leak path there.  That is why we often see folks install a Caseal externally.  This brings a 'belt and suspender system' to bear.  With both systems in place, that casing pipe is protected.

     Caseal is a heat shrinkable wrap around product for externally sealing the casing to carrier connection.  The Caseal is coated with an aggressive mastic sealant that bonds well to all known pipeline coatings and forms a tight seal; preventing air and water ingress.  The Caseal utilizes a fiber reinforced heat shrinkable backing specifically designed to offer superior penetration and abrasion resistance.  Caseal is also fully designed to withstand common pipe movements.

Installed Caseal

     Caseals have been used for more than two decades now.  In spite of there being thousands of installs per year; I've never heard of a single failure.  Not one. 

Advantages and benefits of the heat shrinkable Caseal (Casing Seal) product:

• Fiberglass reinforced backing provides high mechanical resistance and high recovery capacity.
• 65% shrinkage ratio gives it the ability to conform to high casing/carrier transitions; reducing inventory and logistics costs.
• Caseal resists a wide range of environmental and mechanical forces; putting a reliable moisture proof, extremely tough seal in place.
• Specially formulated sealant ensures a strong bond and tight seal to virtually any substrate.  This sealant maintains its elasticity and sealing characteristics over a wide range of temperatures. 
• Sealing adhesive automatically flows and repairs minor mechanical damage.  This is called the self healing effect.   
• Zipper closure system allows for a fast and easy wrap around installation.
• Caseal can be used when casing pipe is not concentric to the carrier pipe.
• No special equipment is required - fast, easy and low cost installation. 

Caseal Product Thickness

     Caseal is a thick product.  The backing when fully and freely recovered would be 3.25mm thick.  The adhesive as supplyed is 1.2mm thick -- and would be significantly thicker than that with a full recovery.  Beyond that, the backing is radiation cross linked which gives it superior abrasion resistance even beyond what you would see in a 3.25mm thick product.

Just a few of the available sizes for Caseal

     Caseals can be manufactured for any casing size.  There is virtually no limit.  Here we see just a few examples.

• A casing seal for a 50" casing could shrink all the way down to a 20" carrier.
• A casing seal for a 44" casing could shrink all the way down to an 18" carrier.
• A casing seal for a 40" casing could shrink down to a 16" carrier.
• A casing seal for a 20" casing could shrink down to a 10" carrier.

     There is an awful lot of shrink in these things.  Please feel free to call me to discuss your specific casing seal needs.  We can help.  We are reliable.  We know what we are talking out.  A pretty good combination.

Steve Simpson - 936/321-3333
steve@jsicoatings.com

WPC120 Shrink Sleeve

High Temp Shrink Sleeve WPC120

Rated for use at 120C (251F) WPC120 is our highest rated shrink sleeve

     WPC120 heat shrinkable wrap around sleeves are designed for corrosion protection of girthwelds on buried pipelines operating at temperatures up to 120C.  WPC120 sleeve have a thick radiation crosslinked polyolefin backing coated with a high shear strength thermoplastic hotmelt adhesive.  during the installation the adhesive melts and flows, filling surface irregularities, bonding to metal and adjacent coated surfaces.
   
     At operating temperatures the adhesive and backing form a solid, tough, well bonded coating.  The flexible closure is coated with a high shear strength adhesive and is normally supplied separately with the sleeve; however, it is available pre attached to the sleeve in the unisleeve construction.

     To install, wrap the sleeve around a clean, preheated pipe (230C minimum).  A flexible closure forms the sleeve into a tube.  The sleeve is then torch shrunk and installed with simple tools.  No powder, primer or sophisticated equipment is required.  However, an induction heater can be used to reduce preheat time.

     WPC120 sleeves resist abrasion, impact and penetration, yet remain flexible even at very low temperatures.  No rock shield is required.

     WPC120 sleeves resist temperature cycling, soil stresses and hydrostatic pressure.  They demonstrate high resistance to ultraviolet light, fungus, cathodic disbondment and chemical attack by common fluids and solvents.  WPC120 sleeves are compatible with FBE, PE and most other high performance pipe coatings (but not PP unless a mastic material is used as the bonding agent).  The product has a long shelf life and is unaffected by typical storage conditions.

     

Duct Band Heat Shrink

Heat Shrink for Duct Bands

     Thermofit Wraparound Duct Bands (TWDB) is Raychem's (now called Covalence) product fpr solving the problem of costly joint leaks in air conditioning duct systems.

     This duct sealing band, made of cross linked polyolefin heat shrinkable material, is precoated with a hot melt adhesive.  When heated in excess of 250F, TWDB shrinks and the adhesive melts, forcing it into all surface irregularities.  Mechanically strong, pressure tight seals are provided. 

     Ducts can be assembled on the floor and raised into position shortly after installation.  TWDB's cut to length system keeps inventory cost minimal by eliminating the need for multiple sizes.  Its wrap around design makes it suitable for flat oval and rectangular duct as well. 

     Used in high velocity systems operating up to 158F, TWDB is non toxic and resistant to solvents and vibration.  Shelf life is unlimited.  This product offers an efficient, neat and permanent method for sealing duct joints, all at a low installed cost. 

     As you see here, the installation procedure is quite simple. 
1:  Cut TWDB to appropriate length.  Recommended overlap is 2 inches onto itself.
2:  Using a heat resistant tape (supplied) secure the TWDB end by taping it in place to form the TWDB into a circle (or rectangle).
3:  Using a standard propane torch, heat TWDB on all sides until it has shrunk uniformly and adhesive is showing at each end.  

Shrink Sleeve Installation Tools

Shrink Sleeve Installation Accessories

     Covalence (formerly Raychem) heat shrinkable sleeves require very few accessories or installation tools to put on.  That being said, there are a number of things we consider to be accessories that are either required for installation - or can be handy to have on hand - or could be necessary if certain conditions exist (damage to a mainline coating, etc). 

     Here is a list and explanation of the different things we consider to be tools and accessories that we sell regularly.

JS-2601 - If you want to install shrink sleeves, you're going to need to have a proper torch for that install.  Rosebuds will not work.  Cutting torches will not work.  You must have a propane torch that is able to put out a broad, bushy, yellow flame.  Working off of bottle pressure will also not be great, so you want to be certain you have a regulator.  Beyond that, you want a long hose (size does matter) because you don't want to be lugging your bottle all over the place.  Our JS 2601 Torch comes with torch head, torch handle (with pilot light), 30 foot hose and regulator.

Silicone Roller - One of the final steps during installation of a heat shrink sleeve is to use a silicone roll the overlap area of the shrink sleeve -- and to have on hand in case the installers do a poor job and inadvertently trap an air bubble somewhere (easy to see with a visual inspection). 

S-1301M Bulk Epoxy / Calibrated Pumps / Primer 15 Kits - S1301M is our two part epoxy that is designed specifically to be used with our DIRAX product, our HTLP60 product and our HTLP80 product.  It can and has also been used with WPCT, WPC100M, Flexclad and other products.  It is most commonly sold in the S1301m Primer 15 Kit (designed to coat 15 square feet of pipe) but can be used in larger projects in its bulk form in order to offer a more economical solution.

Epoxy Heater and Blanket - when working with epoxy in cold weather, it is imperative that the epoxy be warm.  Much like honey, epoxy gets much thicker in cold weather and can even be so think that it is difficult/impossible to mix properly.  With smaller kits, simply keeping the epoxy in a truck can be enough to manage temperature, but with the larger bulk kits, that often won't be the case.  In those cases, you will often want a drum heater on hand to keep the epoxy properly (but not over-) heated.

Bulk Epoxy Accessory Kit - When using the bulk S1301M epoxy, you will need separately:  mixing stick, mixing cups, applicator pads and gloves for hand protection.  This kit contains 100 of each.

Filler - we keep multiple sizes and variations of butyl mastic on hand.  This comes in handy for many different applications including:  packing mastic on a large step down to ease the shrink sleeve transition; packing mastic around bolts of a flange to offer full protection, packing mastic on a small casing pipe to give a Caseal something to shrink down to when the shrink ratio will not quite meet the requirements, things like that.  It is just handy to have around - regularly sold in 10' and 20' lengths.

Perp Tape - stands for Poly Ethylene Repair Patch.  Used to repair damage to factory applied three layer PE coatings.  Much like cutting a patch out and fixing your jeans - this is a roll of material where installers cut custom patches to cover and exceed damaged area to PE line coatings.  Available in both 60C and 80C varieties, PERP is regularly used for repair.

Perp Melt Stick - much like an FBE repair stick, PERP Melt Sticks are used to repair pinhole type damage to PE coatings.  Simply melt the adhesive and pack it into a small damaged area in order to perform the repair.

FBE Repair Sticks - sold in 5# boxes; these are the green sticks used to repair minor damage to FBE coatings.  This could be some physical damage - or damage caused by jeeping the line. 

Thermaclad

Thermaclad - Covering for Insulated Pipes

Thermaclad installed over insulation

    
     I should mention right here up front - Thermaclad is actually a product that has been discontinued.  We have seen it replaced by products like TWDB and other options which can be installed over insulation; protecting the insulation by installing a PE jacket on the outside.   We have a number of options so this is something we really need to have some back and forth with either through telephone or email.

     Thermaclad covering was a heat shrinkable tape made of crosslinked polyolefin and lined with an adhesive coating. The covering is wrapped around the pipe in a spiral configuration.  When heated, the tape shrinks as the adhesive melts and flows through the overlapped areas, creating an environmental seal around the insulation. 

    Thermaclad covering protects the pipe insulation against damage from moisture, as well as acids, bases and solvents.  The polyolefin exterior is rugged enough to resist tampering and mechanical abuse, yet flexible enough to wrap easily around the awkward shapes of elbows, tees and valves.  The product is compact and simple to repair. 

     Installation of the Thermaclad covering requires only a torch, a knife and light gloves.  The product is suitable for use over all thermal insulation materials.  It also eliminates the need for multiple sizes of metallic lagging and clamps, thus greatly reducing inventory space and costs.

SZAR Shrink Sleeves

SZAR Splash Zone Shrink Sleeves

     Szar (Splash Zone and Subsea Corrosion Protection for Conductor Connectors) is designed to completely seal offshore conductor connectors exposed to splash zone and subsea environments.  The installed sleeve encapsulates the connector and bonds to the conductor on either side.  The product prevents seawater from entering the connector joint and causing internal corrosion. 

     Cathodic protection is ineffective in the splash zone and on recessed areas such as the inside connectors on the subsea portions of conductors.  Effective corrosion protection for all connectors above the seabed can be achieved by using SZAR connector protection sleeves. 

     SZAR wrap around heat shrinkable sleeves are constructed of fibre reinforced, modified polyolefin.  They are precoated with a high shear strength, hot melt adhesive that chemically bonds to a two part epoxy primer.  The system provides mechanical strength and exceptional long term adhesion to steel. 

     The unique construction of the SZAR sleeve provides a tough, split resistant, low profile coating capable of withstanding the rigours of offshore installation and long term exposure to constant wave action, abrasion and impact.

     SZAR sleeves are heat shrinkable and they easily accommodate diameter differences between the conductor and connector.  Special filler strips can be provided to accommodate grooves and diameter transitions on connectors.  The filler strips soften during installation to conform to the surface of the connector and fill possible voids. 

     High performance coatings require grit blasting for effective surface preparation.  Although this can be done offshore during conductor stringing, it is much simpler to grit blast the connectors onshore and apply a coating of SZAR Epoxy Primer (S1301M).  This process will maintain the surface profile and greatly simplify offshore operations.

     To install offshore, simply preheat the connector with a propane torch to remove moisture, hand apply a second epoxy primer coating and wrap and shrink the sleeve.

JST / JSW

JST and JSW

     Once upon a time, we had a telephone call from a customer who had a very specific need (isn't that often the way that new products and applications are born?)  This was some kind of a ship builder who was wanting some type of a shrink sleeve to bring physical protection to a sub sea drive shaft of some kind.  I should be honest here and say that I don't honestly know a whole lot about this application.  I have seen photos before, but I was not involved in the development of the product.

     In this case though, what was needed was some kind of a shrink sleeve to wrap (sometimes slide) into place around an Ovako coupling and bring some amount of extra physical protection to that coupling for some period of time in order to prolong its life by some amount of time.

    I apologize, I know this is incredibly vague...but it is all I've got! 

     So the JST product was born.  JST is the nomenclature for the product that will be supplied as a tube, meaning it will be slid into place and then installed using a torch (above water level of course).  JSW is made from the same exact material, but is actually a wrap around product that wraps around that coupling and is then secured using a nylon zipper (already sewn into the product). 

     Both JST and JSW are made with the same base material -- CCS Weave.  CCS Weave is the product that we use to manufacture both our Caseal and our Flangeseal products.  Therefore - JST and JSW are both made with a high expansion, fiber sheet reinforced, radiation crosslinked polyolefin.  This material is coated with an aggressive mastic sealant that bonds to most all known pipeline coatings (and bare steel).

    

Three Layer Field Joint Coating

TLPE Field Joints

     Worldwide, two and three layer polyethylene factory applied coatings are very common.  In the USA, the decision is generally made to use only one layer PE coatings (FBE).  This is a little bit ironic because a normal TLPE factory applied coating is going to use FBE as the primary corrosion coating, then add a layer of an adhesive and then an outer layer of a PE to improve many technical aspects of that coating.  So in a sense, the USA is often using FBE only as a coating, while other parts of the world use FBE + +.   Whatever is decided though, it is always necessary to be aware of the critical nature of the field joints on a pipeline project.  Field conditions are not factory conditions; there is a lot that can go wrong there.  When considering a three layer field joint coating for a field joint (whether that will be used with TLPE factory applied coating or simple FBE coating), HTLP60 is an ideal product for field joint protection of oil and gas pipelines.

Installed HTLP60 shrink sleeve

           So how does this go in the field?  What is the installation like? 

1. Pipe of course has to be clean.  Any coating is only as strong as its weakest bond; the bond of mud to steel is not a strong one...
2. Preheat the steel and adjacent line coating.  The goal here is to get all of it to something in the 140-160F range.  Read this article about our S1301M to find out why this is important.
3. Mix and apply the S1301M Epoxy.  What is included the S1301M Primer 15 Kit?  A can, B can, mix stick, gloves, applicator pad.
4. Wrap the sleeve around the still wet epoxy.  No force curing here. 
5. Secure the closure strip.  The closure forms the sleeve into the shape of a tube during the shrink process.
6. Shrink the HTLP60 sleeve, using a broad, bushy flamed torch.  You want to shrink circumferentially, around the pipe (two installers for 12" pipe and larger).  
7. Check for signs of proper install:  no cold spots or dimples; weld profile and factory coating step down visible; adhesive flow at both edges.

     There you have it, fairly simple and a truly superior coating when compared to most of the other options out there.  

Sealing Cathodic Protection Wire Connections

Sealing a CP Cable Connection

    Time is money.  That is a reality in this world.  When sealing up a cable connection, you have many options available to you; everything from wrapping to shrinking to curing products.  Here is something you may not have seen before:  a snapping product: GHFC. 

     That is actually GILS in that video, but the GHFC is based on the same technology, same gel closure, just slightly smaller in length.  This is an H frame gel closure for low voltage power cables running at 1000 volts or less.  It provides a fast and simple method for insulating and environmentally sealing low voltage cable taps and splices. 

     This closure uses Tyco Electronics / Raychem's innovative Power Gel sealant material to seal and protect the connection from moisture ingress, corrosion and pollution.  It is ideal for both underground and overhead applications and is especially useful for street lighting applications. 

     Simply place the connection on the closure and press the closure together.  It is that easy, no tapes, mastics, tools or mixing required.  Not heating, no curing, no wrapping.  It can quickly and simply be installed with one hand.

     Available in three different sizes:  GHFC 1-90; GHFC 2-90 and GHFC 3-90.  Contact us for pricing and delivery information. 

Heat Shrinkable Tape

Flexclad Heat Shrink Tape

     Whereas coating a girth weld at the field joint can be a very simple thing (as long as you are selecting the correct coating for the application); coating a pipe bend or a fitting of some kind can be a lot more challenging.  Cold applied tapes can be very simple to install; but you're going to sacrifice some performance.  Heat shrink sleeves are proven to be reliable long term coatings, but will not work on a pipe bend without some customization by your crews (which can be quite risky).  So why not combine the simplicity of a cold applied tape with the proven technical reliability of a heat shrink sleeve?  That is exactly where Flexclad was born.

Installed Flexclad on a 90

     Flexclad is spiral wrapped around the cleaned and preheated substrate, overlapping itself according to coating specifications; then shrunk down with a propane torch to form a contiguous coating.  As the Flexclad is shrunk down, the adhesive layer flows, filling all cracks and potential voids as it does.  As the shrink tape cools, the adhesive returns to its tougher, harder, original state though it will now be fully bonded to the substrate (bare steel and adjacent factory applied coating). 

     This product can also be installed on fittings and other abnormal substrates.  Generally available in 2", 3" and 4" widths all rolls are supplied in 50 foot lengths.  Full nomenclature for each size is:

2" = Flexclad 50-15000/165
3" = Flexclad 75-15000/165
4" = Flexclad 100-15000/165

     All sizes are regularly stocked at my warehouse in Conroe, TX and can be available for immediate shipment.

CPSM 195/102-1500/87

CPSM 195/102

     CPSM is a high expansion, tubular sleeve with an internally coated mastic sealant.  To get specific with the nomenclature, CPSM stands for Corrosion Protection Sleeve and the M stands for metric (since that is how it is sized...in mm.)  Looking at the sizing, the 195/102 is quite simple.  The 195 is the ID of the tubular sleeve as supplied (195mm = 7.6771653".)  The 102 is the ID to which the shrink sleeve will shrink down (102mm = 40.15748".)  It can actually shrink slightly smaller than that even as that is dictated by the backing shrinking down.  As the backing shrinks down, the mastic adhesive actually thickens resulting in a solid seal there.

     CSPM is a thick walled, radiation crosslinked, heat shrinkable polyolefin.  It has historically been used to encapsulate mechanical couplings and straight pipe surfaces with a strong, impervious seal.  While the sleeve conforms to the shape of the coupling and/or pipe, the sealant softens and is forced into all surface irregularities, ensuring a permanent environmental seal.  CPSM sleeves are are easy and fast to install, bonding effectively to metals, plastics and other materials.  Should the backing be mechanically damaged, the sealant will fill the damaged area, preventing corrosion. 

     CPSM also has a high resistance to bending, impact, abrasion, penetration, corrosive gases or fluids, disbonding and long term storage.  The high shrink ratio allows the CPSM 195/102 to be used on a wide range of different substrate configurations and sizes.

     Installation is carried out in just a few short steps:

1. Slide CPSM into place before welding or attaching coupling.
2. Clean weld area with a hand or power wire brush to remove rust, dirt and foreign materials.
3. Preheat field joint and adjacent factory applied coating to 140F to 180F.  
4. Remove sleeves inner protection release paper and center sleeve over area to be coated.
5. Heat sleeve beginning at center working torch circumferentially (around the circumference of the sleeve) heating evenly.
6. Shrink toward one end; return to middle and then shrink toward the other end.
7. Sleeve is fully and properly installed when:  there are no cold spots or dimples on sleeve surface; weld bead or coupling profile can be seen through sleeve and mastic flow is evident at both edges of sleeve.

     If this sounds like the right product, but the sizing is not what you need, please contact us to discuss other options that we have available.  steve@jsicoatings.com

ASE-4

Anode Splice Encapsulation Kit

     How do you seal up a standard split bolt or a compression connector?  It sounds like it should be simple (spoiler alert:  it is) but as soon as you begin to start to do it; you realize it is a bit more complicated.  Two cables moving into a connection that has only one cable on the other side.  That a scenario that has disaster written all over it.  Sure you can wrap each individual cable and then press them together and then wrap the entire thing; but that configuration is likely to leave leak paths all over the path.  Leak paths are not good.  Leak paths are bad.  Leak paths are very bad.  Beyond that, you'd end up with multiple installation steps, multiple components and you'd be heavily reliant on the skill of the installer. Yes, there are many incredibly gifted electricians on this planet.  Unfortunately, like any profession, there are also a few out there who might simply be having a bad day.  That is where our Anode Splice Encapsulation Kit (ASE) comes in.

Fully installed ASE

Cross section of an installed ASE

     The ASE is coated with a very thick self encapsulating adhesive that fills and flows to seal up every crack, crevice and possible leak path that might threaten your cable connection.  ASE is designed specifically for protecting the anode splice connections of HMWPE and HDPE (and others). 

     The ASE installation is very simple, requiring no special skills or equipment.  Rapid, reliable and repeatable installations are a hallmark feature of this product.  In addition, the ASE-4 can cover a wide range of cable sizes, reducing inventory requirements and simplifying the entire process of purchasing this material.  There is no labor required for taping and there is no time wasted with mixing components or waiting for cure times.  ASE-4 can be installed in temperatures as low as -40F.

     Full installation for an ASE-4 can be completed as quickly as 2-3 minutes.  Direct burial can occur immediately upon completion of the full installation.  The installed product is mechanically strong, electrically insulated and sealed from moisture and contamination.