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مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating

أساليب حل و إصلاح مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating دون إحداث ضرر للطبقة العازلة

Sleeves & Liquids

Application

(99% of the cases in the world)

Heatshrink sleeves

–PE 3 layers
–PP 3 layers
–FBE
–PU
Liquids (Epoxy/PU)
–FBE
–PU

Mill-applied 

3 Layer Polyethylene coatings

مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating

Technologies:
–Polyurethanes
–Epoxy
•Manual application or machine (Spray)
•Single or multiple passes to reach required thickness
مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating
 
3 layers
–Epoxy
–Adhesive
–Polyethylene
•Replication of mill-applied 3-layer PE coating
•Factory made design/system
Function of the intermediate adhesive
Maximise the adhesion to:
Polyethylene (Mechanical Protection) & Epoxy (Corrosion Protection)
Good shear resistance
Sleeves
–Epoxy
–Adhesive
–Polyethylene
Reconstructs mill-applied coating performance
Liquids
Sole adhesive to bond to 4 materials:
–Steel
–Epoxy
–Adhesive

Polyethylene

مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating

•Adhesion Epoxy-Metal: 20-30MPa (ISO = 10 MPa)
•Adhesion PU-Metal:10-15 MPa (ISO = 10MPa)
•Adhesion PU / Epoxy - PE

•Not compliant with ISO 21809-3

•Adhesion of Heat Shrinkable Sleeves on Steel is the same as Adhesion on PE
مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating
 
cracks on interface

Line coating

determines the choice of girthweld protection.

Heat-Shrink

Sleeves

- PE 3 layers
- PP 3 layers
- FBE
- PU

Liquids (Epoxy/PU)

- FBE

- PU 

Heat-shrink Sleeves

•Surface Preparation
•Pre-heating
•Mixing and application of Epoxy
•Sleeve Application
•Shrinking (Torch)
•Dielectric Testing (identical voltage)

(Irrelevant of the ambient conditions)

Liquids

•Applicator Protection (Spray)
•Prepare equipment (Spray)
•Surface preparation
•Pre-heating (especially PE)
•Appropriate mixing
•Roll or Spray
•Check and build up thickness (3 x 500 microns)
•Polymerization & Protection
•Dielectric Test (different voltages)

(Ambient Conditions RH < 80% to avoid Blistering)

Pinholes are a consequence of entrapped air and moisture

مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating

مشاكل انحباس فقاعات هواء تحت الطبقة العازلة PE Line Coating

Welds / day (48”) : 50 - 170 (0,6 - 2km)

Sleeves

–Surface preparation (4-5min)
–Crew of 4 people
–6 joints / hour
–60 joints / day / crew
–1 crew for +/-50 joints
–3 crews for 170 joints

Easy logistics

Liquids

–Surface preparation (4-5min)
–3 passes (1500 microns)
–3 to 4 minutes coating interval
–10 to 15 minutes / joint
–40 joints / day / crew
–1 crew for +/-50 joints
–4 crews for 170 joints
Complex logistics
(Machine – product – storage – pot life)

Planning is driven by welding cycle time

Diameter: 48” – Cutback: 150mm

Sleeves
HTLP80 EN12608-UV

– Overlap: 50mm
– Thickness: 2,8 – 3 mm
– 100 / joint

Liquids

Epoxy Powercrete R60 & R95

–Overlap: 100mm
–Thickness: 1000-1500 microns
–Wastage: 50%
–5 liters (8kg) / joint

6-10US$/kg: 100-160 / joint

Polyurethane

–Overlap: 100mm
–Thickness: 1500 microns
–Wastage: 50%
–6 liters (9,6kg) / joint

5-6US$/kg: 100-120 / joint

- Superior system: Adhesion to PE
- Compliant with international standards

- Does not cause delays (preference of contractors)

- Comparable budgets

This solution ensures the longest service life

Diameter: 48” – Cutback: 150mm

50 – 55 US$ / joint

Liquids

Epoxy Powercrete R60 & R95

–Overlap: 100mm
–Thickness: 1000-1500 microns
–Wastage: 50%
–5 liters (8kg) / joint

6-10US$/kg: 48-80US$ / joint

Polyurethane

–Overlap: 100mm
–Thickness: 1500 microns
–Wastage: 50%
–6 liters (9,6kg) / joint

5-6US$/kg: 48-58 US$ / joint

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