DIRAX Application Instructions

 DIRAX Installation Guideline

    DIRAX is a relatively simple installation.  It does not require any significant skill.  A few of the common tips that we say over and over and over at training sessions are:  1)  You want a broad bushy yellow flame to shrink the sleeve (this requires that you have a regulator of some kind) and 2) Your torch needs to ALWAYS be moving - you can't stay in one spot for too long and you want to make sure it is the yellow flame in contact with the sleeve; not the blue flame and not the 'clear' flame right where it comes out of the torch.  

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

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 scrape

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

Grid or sand blast the adjacent pipe coating over a distance of at least 200 mm (8"). The total width should be approximately 50 mm larger than the width of the Raychem supplied DIRAX sleeve. Note: prior to blasting, it is recommended to preheat the exposed steel to 40 - 50° C to avoid flash rust formation

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

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. For easy disposal, it is recommended to pour this mixture back into can B and mix for another 30 seconds. As such, the remaining epoxy in both cans will cure and can be easily disposed off. Follow local regulations for safe disposal. 40°C 20°C 2 min 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. When necessary, keep the epoxy primer at a heated place or use a Raychem epoxy heater.

Preheat the bare steel surface and adjacent coating to minimum 70°C (160°F), using propane torches. Adjust flame length to approximately 20" (500 mm). In cold conditions extra heavy preheat torches can be used. Check preheat temperature with a contact pyrometer

Using the supplied applicator pad, apply the mixed epoxy primer over the entire surface to be covered. (When PE line coating is used, no primer should be applied over the polyethylene line coating.)

Immediately after application of the epoxy primer, and while the epoxy primer is still wet, loosely wrap the DIRAX sleeve centrally around the welded joint. If present, remove the protective release plastic from the adhesive side of the DIRAX sleeve.  Wrap the sleeve (adhesive side down) around the area to be coated. Make sure the sleeve overlaps the end of the inner layer by at least 50 mm (2”).

Preheat the inside adhesive layer just next to the closure for a few seconds, and press down on the sleeve end to make it stick to the other end.

Using a Raychem propane torch with a flame length of approximately 500 mm (20”), start heating one end of the closure area.

Immediately pat it down firmly with a gloved hand. Continue heating and patting every 10 cm (4”) until the whole patch area is finished.

Start heating the sleeve at the side of the leading edge, the side that first comes in contact with the ground forces. Move the torch continuously in a paint brush motion all the way around the sleeve

After you have finished heating the side at the leading edge, recover the remainder of the sleeve by heating toward the other end of the sleeve

During shrink down, check adhesive flow with finger occasionally. Wrinkles should disappear automatically

After the DIRAX sleeve has shrunk into the joint area and while it is still hot and soft, run a small hand roller over it to push out any trapped air. Pay particular attention to the weld and cutback area. Reheat areas if necessary.

The sleeve is fully recovered when all of the following have occurred: - The sleeve has fully conformed to the pipe and adjacent coating. - There are no cold spots or dimples on the sleeve surface. - Weld bead profile and other step downs can be seen through the sleeve. - Adhesive flow is evident on both edges, after sleeve is cool.

An 80 mm (3.2”) wide sacrificial sleeve is installed on the leading edge to function as a wear cone during pull thru of the pipe. Start by heating the leading edge area to 70°C (160°F).

Wrap the leading edge sleeve over the transition DIRAX - mill coating. Make sure that the closure is placed away from the main sleeve closure. Preheat the inside adhesive layer just next to the closure for a few seconds. Press down to make it stick to the other sheet end

Heat the closure area and immediately pat it down with a gloved hand.

Shrink the leading edge sleeve down by moving the torch all the way around the pipe in a paintbrush motion. Make sure the sleeve has fully shrunk and adhesive flow is evident on both edges.

Smooth down the edges of the sleeve with the Raychem silicone hand roller. Sleeve is fully recovered when all the following have occurred: - The sleeve has fully conformed to the pipe and adjacent coating. - There are no cold spots or dimples on the sleeve surface. - Weld bead profile and other step downs can be seen through the sleeve. - Adhesive flow is evident on both edges after sleeve is cool. Before the DIRAX can be exposed to the soil forces the joint should be cooled down to ambient temperature

DIRAX for Standard Field Joints

 DIRAX for Straight Line Buried Pipe?

An Installed DIRAX Sleeve

     In this world that we live in; there is a phrase that is probably not used enough in my opinion because of the lazy, negative connotations associated with it.  That phrase is "good enough."  Maybe I'm talking about exercise.  For some folks; running two miles, 4 days a week is "good enough."  For other folks who are training for an ultra marathon, eight miles a week is nowhere near good enough!  They are running 35-40 miles per week!  That is their 'good enough.'

     Likewise, we could look at auto insurance.  For many people; having standard car insurance with $100,000 worth of coverage is good enough.  If you were someone like Bill Gates or Elon Musk, you'd likely want something like $1,000,000 to feel like your coverage is good enough (imagine the attorneys lining up if one of those two caused a bad car accident.

     Final example:  I would expect for most people, scoring a 95% on a test is 'good enough'.  Most people are going to feel like a 95% is definitely good enough.  Those folks in the world (and there are some) who are feel like only a perfect 100% is good enough are probably having a very difficult time operating in a world where perfection is very often unattainable.

     Those same sort of principles can apply to just about every single aspect of life.  Pipeline coatings are no different.  Without getting into the details; let's look at factory applied coatings.  Common options are FBE, Dual layer FBE, FBE with an ARO, three layer PE, three layer PP, coal tar enamel, etc.  Each has various strengths which can be tied to technical performance, cost, availability, etc.  Pipeline engineers are regularly answering the question (for themselves) - What is good enough for my application? 

     Field joint coatings are no different.  Decision makers are deciding between cold applied tapes (yes - still plenty of cold applied tape coatings going on field joints in the US) to FBE to various two part epoxies, to shrink sleeves to wax tapes to geotextile tapes (essentially straight mastic with a porous backing).  Those decision makers, whether they know it or not are asking and answering the question:  what is good enough for these specific pipeline conditions?

     As you would likely imagine, with this 'good enough' criteria, if you ask 100 different people what (in their opinion) is good enough; you will likely get 95 different answers.  

     For some, few people, they aren't interested in good enough.  They are acutely aware of what their company is spending on pipe, construction, factory applied coatings, labor, etc.  They are also acutely aware of what can happen if a bad decision is made or a poor corrosion coating solution is chosen.  Bad, bad things.  For those people, they analyze their options and they choose to install DIRAX on all of their field joints (not just the directional drilling portions).  Why not put on the best to protect our assets?  It looks like DIRAX is the best.  I want DIRAX on every joint.  It happens more than you'd think!  Not everyone is out there looking for the cheapest options.

Covalence Shrink Sleeve Rolls - in stock

 Raychem / Covalence Shrink Sleeve Rolls

IN STOCK

     One of JSI's greatest strength is our inventory.  We know that the products we sell are very often last minute needs that were forgotten earlier in the construction planning process.  We work to keep our 20,000 square foot warehouse full of material so that we are ready to meet your demands....exactly when you need your demands met.  Need product in Florida in two days?  We can do that.  Need a box of material overnighted to New York?  No problem.  Need to swing by two hours from now to pick up a pallet of material?  Done, see you in a couple of hours.

       But in this article, I'm only talking about rolls of material in stock ready to go.  That could mean you're buying rolls for your project -- or it could mean we are converting those rolls into sleeves for specific pipe sizes (which is absolutely what we recommend).

WPCT:  The Covalence wrap around, mastic coated sleeve designed for pipelines operating at or below 140F.  We stock WPCT in 11", 17", 24" and 34" widths and we are capable of making any custom width less than 34".

WPC100M:  The mastic sleeve for elevated temperatures.  Rated at 176F (or 212F offshore or under insulation).  We stock WPC100M in 11", 17", 24" and 34" widths.

WPC120:  The high temp sleeve; rated for use at 251F.  We stock WPC120 in 11", 17", 24" and 34" widths.

DIRAX / ROCS / SZAR:  The high performance sleeve most often used on road bores and directional drilling applications.  We stock DIRAX i 12", 17", 24" and 34" widths.

TWDB:  Thermofit wrap around duct bands; sold in rolls that are 165 feet long.  We stock TWDB in 3" and 4" widths.

Flexclad:  Heat shrinkable tape; sold in rolls that are 50 feet long.  We stock Flexclad in 2", 3" and 4" wide tape.

HTLP60:  Three layer coating system for lines operating at or below 60C.  We stock HTLP60 in 11", 17", 24" and 34" widths.

HTLP80:  Three layer coating system for lines operating at or below 80C.  We stock HTLP80 in 11", 17", 24" and 34" widths.

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.

DIRAX Shrink Sleeves | ROCS Shrink Sleeves | SZAR Shrink Sleeves

What is the Difference Between DIRAX Shrink Sleeves, ROCS Shrink Sleeves and SZAR Shrink Sleeves?

     Once upon a time, in the far way land of Menlo Park, California a company called Raychem ruled the world (when considering heat shrink and splicing technologies).  Their products spanned multiple technologies including pipeline, electrical, telecom, mining and more.  Innovation and invention were the names of the game and Raychem invested 10-12% of their GROSS SALES into product development every single year.  With some of the brightest engineers and chemists in the world working throughout the different divisions, new product technologies were discovered at an incredible rate.  It was at that time that some genius working on developing a telecom product invented an amazing backing material called ROCS 60e.

    

ROCS 60e - an incredibly tough shrink sleeve

     ROCS 60e was unlike any heat shrinkable backing ever created - and unlike any that has since been created.  It is absolutely one of a kind offering unparalleled penetration resistance, thickness, abrasion resistance and impact resistance.  The product was so incredible that Telecom began sending out samples to the other divisions of Raychem in order to find out what other industries might benefit from this breakthrough technology.

     When the Pipeline division caught sight of it, they went bananas.  This was unlike anything else on the market in the pipeline world, there was nothing that could match it technically in terms of the backing.  The pipeline had a little work to do though - in the pipeline world; the backing is only half of the product; R&D was going to need to develop an adhesive that could do justice to this backing.  So they got to work.  In the mean time, R&D involved sales who could begin exploring different applications for this ROCS material.  That was not a problem, there were many.  Of course, once marketing got involved; things got a little bit complicated (isn't that always the case?).  Marketing decided that every application utilizing this ROCS material needed to have a different name.  At that time, in that world, different applications had different pricing levels - and the plant wanted to be able to sell this product into the pipeline coatings world (typically a lower margin business) AND have it available for traditionally high cost applications like coating pilings.  And so it was that the product called ROCS 60e became a product of three names. 

     For the Pipeline Directional Drilling world; they called the product DIRAX.  The combined the sleeve with an epoxy primer (S1301M) and a leader strip (3" wide shrink sleeve to act as a wear cone) and packaged it as a DIRAX kit.

     For the offshore riser / splash zone market; they called the product SZAR (originally sort of called SeaZar which they may have thought was clever - and which may have been shortened to CZAR but then marketing probably pointed out the flaws in offering that product in places like the old Soviet Union).  SZAR is also used with the S1301M epoxy....but they are purchased separately as two different line items.

     Finally, for the field joints of standard pipelines where the soil conditions will be incredibly challenging and rocky; the decided to call the material ROCS (simply dropping the 60e from ROCS 60e).  Like the SZAR above, ROCS is used with S1301M epoxy primer and ordered as its own line item. 

     So, one amazing product -- three different names.  I know that the name situation can be confusing...but the installation and performance of the product is simple.