Corrosion protection of pipelines - Napa Teknapatek.co.th/pdf/pipeline_products_catalogue.pdf · 285 mm (11.25 inches), 450 mm (17.75 inches), 600 mm (23.50 inches) and 870 mm (34.25

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Corrosion protectionof pipelines

Girth weld coating

Pipe coating

Coating of fittings

Coating repair

Cathodic protection

Accessories

New technologies

Contents

Tyco Adhesives, a world of solutions

The principle of heat-shrinking, a technicalexplanation

Advantages of Raychem heat-shrinkableproducts

Girth weld coating

1. Tubular product TPS, TPSM C-30

2. Two-layer coating for pipes with WPCT, WPC B30, ambient operating temperature WPC C30, WPCZ

3. Two-layer coating for pipes with WPC B50, WPC C50, WPC65M, elevated operating temperature WPC 100M, WPC 120

4. Three-layer coating for pipes with ambient and elevated operating temperature HTLP60, HTLP80

5. Three-layer coating for horizontal or directional drilling applications DIRAX

6. Product application tables

Pipe coating

Two-layer pipe coating forelevated temperature RAYCLAD

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Corrosion protection of pipelines

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Coating of fittings

1. Bends FLEXCLAD

2. Wraparound sleeve for casings CSEM-F/CASEAL (US)

3. Wraparound sleeve for flanges FCWS-F/FLANGESEAL (US)

Coating repair

Repair system fordamaged PE-coatings PERP

Cathodic protection

ANODEFLEX 1500-01

ANODEFLEX 500

Liquid coatings

Accessories

New technologies

General technical data

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Contents(Continued)

1 Raychem, a world of solutions Raychem, a world of solutionsfrom Tyco Adhesives

Raychem heat-shrinkable productsplay a key role in pipelineinstallations around the world.A comprehensive range answersevery application need.

KazakhstanTrunk and flow linesProduct: Rayclad 120

BrazilProduct: WPCT

KuwaitS1239 epoxy primer applicationon 48 inch live pipeline of 30°CHTLP60/B sleeve wrappingProduct: HTLP60

Saudi-ArabiaSandblasting of steel / PE surfaceProduct: HTLP80 / 1–1.5

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GermanyInstallation with torchProduct: WPC – C50

IranView of pipelinein desertProduct: HTLP60

1 Raychem, a world of solutionsfrom Tyco Adhesives

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Raychem pioneered the heat-shrink process,and Tyco Adhesives works continuously toadvance the technology.Tyco Adhesives products meet the highestquality standards, match the most demandinginternational norms.

IndonesiaProduct: WPC/B

North Sea - offshoreProduct: HTLP60

USAProduct: Flexclad

ChinaProduct: HTLP60

Russia (Siberia)Product: HTLP60

IndiaProduct: HTLP60

2Thermoplastic materials are composed of extremely long molecular chains in arandom arrangement. Their strength depends upon the distance between themolecules and the crystalline nature of the molecular structure. In fact, it is thecrystals that contribute most of the strength.

As the thermoplastic is heated to above its crystallinemelting point (120°C) (248°F), the crystals disappear.The molecules can then easily slip past each other, sothe material flows.

During the investigation of atomic energy, the importantdiscovery was made that exposure of some plasticmaterials to high-energy penetrating radiation cancause permanent crosslinking (intermolecular joining)of adjacent molecules.

This linking results in the chemical bonding of the plas-tic structure into a new three-dimensional matrix. Oncea material has been crosslinked, it will not melt or flowat any temperature. When heated, the crystals disap-pear as before, but no flow or shape change occursbecause the crosslinks act as ties between the mo-lecules. However, the structure remains elastic – whenthe crystals are melted, the material behaves like arubber.

Products that have been radiation crosslinked exhibitperfect elastic memory. They can be supplied in a de-formed or expanded condition. When heated, theyshrink – for example, to tightly enclose an object overwhich they have been placed. This makes them idealfor covering a variety of pipes and pipe fittings, as wellas wires lugs, terminals, connectors and other electricaland electronic components.

The principle of heat-shrinking,a technical explanation

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Tyco Adhesives fabricates its Raychem compounds into their final form andthen subjects them to high energy radiation, thus permanently ‘freezing’ theminto the desired shape. The following illustrations demonstrate what happens tothe molecular structure of crosslinked tubing during subsequent stages ofmanufacture and during application. Next to each illustration is an end view of apiece of heat-shrinkable tubing.

Figure 1 is an enlarged schematic viewof a very small crosslinked section ofextremely long molecules.

Once the tubing has been crosslinked,the next step in imparting elasticmemory is to heat the compoundabove its crystalline melting point. Themolecules are then tied together onlyby the crosslinks.

While hot, the tubing is deformed byapplying internal pressure, thusstretching the crosslinked molecule.

While in this deformed shape, the tub-ing is cooled. The crystals then reap-pear, thereby locking the structuretogether indefinitely in the expandedform. This is the form in which the ma-terial is supplied to customers.

A user reheats the product, melting thecrystals. The crosslinks allow the mate-rial to return to its original shape. Thisis the perfect elastic memory ofcrosslinked material.

After cooling, the crystals reform andthe tubing is locked in its recoveredform. Upon subsequent reheating, nofurther change in shape will take place,unless mechanical force is applied.

Legend

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cross-section of a tubing

crystals

crosslinks

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To provide the optimal solution for each application, Raychem offers a range ofproducts based on an irradiated crosslinked polyethylene carrier, combined witha hotmelt or mastic coating.

The main purpose of the crosslinked carrier, called ‘backing’, is to provide astrong barrier against electrical current, permeation and mechanical forces.

The adhesive assures long-term bonding of the backing to the pipe, and providesadded electrical resistance and mechanical strength.

Thickness of the backing and adhesive depend on the application requirements.

Optimal solutions

In order to protect metal pipe structures in contact with an electrolyte (soil, wa-ter) coatings need to have a high electrical resistance and low permeability tohydrogen and oxygen.

The coating must also be physically strong and chemically stable.

Additionally, the requirements of particular applications, e.g. high operatingtemperature necessitate specific tailoring of pipeline coatings.

Demanding applications

Advantages of Raychemheat-shrinkable products

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chemical resistance

flow and fill

mechanical strength

electrical resistance

hotmelt/mastic layer

heat-shrinkable backing

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For the increasingly common three-layer factory-applied coatings, Raychem hasdeveloped a three-layer field-applied joint coating. To provide a homogeneouslycoated pipe surface in the girth weld area, a layer of two-component epoxy isfirst applied to the pipe surface. A specially designed shrink sleeve is thenapplied over the wet epoxy.

The three-layer coating performs extremely well in resisting cathodicdisbondment. It offers high shear resistance against soil load, and consequentlyensures long service life.

Three-layer coating

To place an order, or inquire about existing orders, deliveries, product docu-mentation and information, call the customer service center for Europe at(32) 16 55 36 00, fax (32) 16 55 36 74 or +1 800 248 7659 Ext 6161 in the US.Product documentation and information can also be found on the Tyco Adhe-sives website www.tycoadhesives.com.

Tyco Adhesives field engineers can provide training and certification for contrac-tors crews, either on site or at Tyco Adhesives facilities.

High reliability, high performance

Raychem has 30 years experience in the development and manufacture ofheat-shrinkable products. Continuous improvement ensures state-of-the-artperformance. Approval by testing agencies around the world guarantees sui-tability for individual applications and field conditions.

• Two-layer and three-layer constructions complement wide range of pipecoatings

• Top quality hotmelt, copolymer coated sleeves resist elevated pipe operatingtemperatures and soil stresses on all pipe diameters

• Mastic-coated sleeves balance performance, economy and ease of installation

• Three-layer sleeves with epoxy primer and hotmelt copolymer, have excellentresistance to both cathodic disbondment and hot water immersion, even atmaximum rated operating temperature

• Fiberglass-reinforced sleeves withstand the high stresses of directional drilling

• Self-healing adhesive flow automatically repairs minor mechanical damage

Low installation cost

• No primer required for two-layer products – install directly on cleaned, pre-heated surface.

• No waiting for primers to cure – install three-layer sleevesdirectly over wet epoxy primer

• Simple tools such as hand brush, power brush or blast-cleaning, propanetorches

• WPC products available in Unisleeve construction – with pre-attached closurepatch.

• Easy-to-understand installation instructions are shipped with every product,while clear product labeling allows rapid on-site identification

Premium service

heat-shrinkable backing

hotmelt/mastic layer

epoxy primer

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4 Girth weld coating

Selecting the sleeve

Pipe operating temperature

Pipe coating type

Cutback distance

Outside pipe diameter

Adverse soil conditions

Raychem heat-shrinkable sleeves are the world leader in corrosion protection ofpipeline girth welds. They are specifically designed to combine ease of fieldinstallation with a level of performance that matches, or exceeds, that of themain pipe coating.

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Pipe laying method

Climate conditions

Recommended pipe preparation

Mechanical resistance class

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As temperature increases, the overall resistance of a coating generally de-creases. Therefore, in order to ensure adequate lifetime, it's important to selecta coating that has been correctly performance tested at maximum operatingtemperature.

Raychem mastic coated sleeves are available for temperatures upto 80°C(176°F), and hotmelt sleeves upto 120°C (248°F).

Raychem heat-shrinkable sleeves are compatible with all commonly used pipecoatings, although somewhat different installation procedures may be required,depending on the line coating employed. The sleeves adhere well to coal tar(CT), coal tar enamel (CTE), asphalt-based coatings, fusion-bonded epoxies(FBE), and all commonly applied polymer pipe coatings – including polyethylene(PE) and polypropylene (PP).

Some polypropylene coated pipes require special Raychem sleeves. Whenusing polypropylene pipe coating, please consult your Raychem representativefor assistance in selecting the appropriate heat-shrinkable joint protectionsleeve.

The Raychem “HTLP” three-layer system is often used on three-layerpolyethylene pipe coatings to provide ‘factory original’ quality to the field appliedgirth weld protection. The same system can also be applied on two-layerpolyethylene.

Different pipe coatings require different coating cut-backs at the welded joints.

Raychem offers heat-shrinkable sleeves in four standard widths:285 mm (11.25 inches), 450 mm (17.75 inches), 600 mm (23.50 inches) and870 mm (34.25 inches).

When buried, larger diameter pipes incur higher soil stress due to the weight ofthe soil above them. These stresses create tangential forces, which in low per-formance coatings tend to cause wrinkling at the two, four, eight and ten o’clockpositions on the pipe. The best way to combat these forces is with high-moduluspolymer shrink sleeves coated with high shear-strength adhesive.

Raychem heat-shrinkable sleeves possess the highest modulus in the industry,while the hotmelt adhesives are made of the finest copolymers. Raychemhotmelt coated shrink sleeves provide the greatest resistance to soil stresses onall diameters. Below 20 inches diameter, Raychem’s high performance masticcoated shrink sleeves often provide a good balance of performance, economyand ease of installation.

In adverse soil conditions where heavy soil stresses, corrosive soils or water-logged areas are expected, the use of soil stress-free coatings with excellentcathodic disbondment and long term water immersion resistance is essential.

Raychem HTLP60, HTLP80, and WPC120 are all outstanding in this respect.They have consistently been rated the best girth weld coatings in tests carriedout by major pipeline companies worldwide.

Project specifications and/or local standards must be observed, when specifyinga shrinkable sleeve for protection of a girth weld. To ensure an optimal choice,the following parameters must be considered:

Pipe operatingtemperature

Pipe coating type

Cutback distance

Outside pipe diameter

Adverse soil conditions

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7 Climatic conditions

8 Recommended pipepreparation

Pipe laying method6 Directional drilling

Directional drilling places tremendous stress on a pipe coating – and especiallyon the girth weld coating.

Raychem DIRAX kits are designed to protect girth-welds in this punishing envi-ronment. The DIRAX system starts with the application of an epoxy primer coat-ing, on top of which the DIRAX sleeve is installed. The sleeve is a fiberglass -reinforced polymer laminate with an extremely high-shear resistant crystallineadhesive. In numerous tests and customer trials, DIRAX surpasses even thetoughest conditions.

Offshore (Submarine Conditions)

For laybarge installed pipelines, Raychem WPCZ or WPC100M are idealgirthweld coatings, being easy and quick to install, and fully resistant to the pourof hot marine mastic infills. They are compatible with all commonly used mainpipe coatings e.g. bitumen, coaltar enamel, FBE, P.E., Polyprop etc. For el-evated temperature lines use WPC100M which has a 100°C (212°F) continuousrating subsea.

For reelship installed pipelines, Raychem HTLP80 has a proven track-record onthree-layer polyethylene coated pipes, even when reeled/unreeled under tropi-cal conditions. For pipe coatings other than polyethylene, please consultRaychem for correct reelship installed sleeve selection.

Extreme climatic conditions (hot, cold, wet, etc.) can have an impact on thesleeve selection and the installation method. In cold conditions it will be neces-sary to organize proper field storage; rain requires a tent. In hot climates, it maybe better to select a high temperature sleeve, even for a low pipe operatingtemperature, as the pipe could be exposed to very high ambient temperaturesfor an extended period during construction.

Pipe preparation depends upon the project specification and the resultingchoice of products. In order to obtain the desired performance, pipe preparationmust be carried out in accordance with the relevant product installation instruc-tions.

8.1. Drying

In some cases it may be necessary to dry pipe before cleaning, in order to makesure that mud does not enter into any surface irregularities.

8.2. Grease removal

If oil or grease is present, this must be removed using a Tyco Adhesives ap-proved solvent.

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9 Mechanical resistanceclass

8.3. Cleaning

The metal surface and the adjacent coating must first be cleaned.

The ideal method is shot- or grit-blasting, which provides a defined surfaceroughness and the required standard of cleaning. In some cases, cleaning witha hand wire brush is sufficient. When using a motor-powered wire brush, careshould be taken that the surface is not polished smooth. Preparation of the pipeends varies, depending on the type of mill coating. On a two-layer PE systemthere is often a temporary end protection, which needs to be removed. Theepoxy layer of a three-layer system can remain in place.

8.4. Preheating

The pipes must be preheated in accordance with the installation instructions ofthe products concerned. In most cases preheating with a gas torch flame issufficient. Inductive Heating is also effective, though normally not required.

Depending on the mechanical requirements of the local or project specification,the appropriate sleeve construction (thickness) is selected. Raychem’s standardproduct matrix copes with all international standards. For special conditions acustomized sleeve construction can be produced.

All of the above parameters influence the type of heat-shrinkable sleeverequired to provide the best performance, ease of installation and value.The following guidelines will help you to decide which sleeve is right foryour application.

For special requirements or applications, contact your Tyco Adhesivesrepresentative.

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4Girth weld straight joints –Selection table for Heat Shrinkable Products

By checking the appropriate parameters, you can easily select the proper product

Selecting the proper sleeve Project specifications and local standards must be considered when specifyinga shrinkable sleeve.

Next to these the following parameters must be considered for selecting theproper shrinkable sleeve:

• Pipe Coating Type:f.i. Bitumen, Coal Tar Enamel (CTE), Cold Applied Tapes (CAT), FusionBonded Epoxy (FBE), PolyEthylene (PE), PolyPropylene (PP),..

• Pipe Operating Temperature:0 - 120°C (0-248°F)

• Pipe Operating Pressure:f.i. 100 mbar = 1,42 psi, >4 bar = 56.88 psi,..

• Pipe Medium:f.i. Gas, water, oil,...

• Pipe Diameter:f.i. 1" or DN25 for steel pipe, 160 mm jacket diameter for insulated steelpipe,...

• Pipe Preparation:surface cleaning: f.i. abrading, brushing, gritblastingobtainable preheat temperature: low (60-70°C) (140-158°F), high (80-100°C)(176-212°F), very high (230°C) (446°F)

• Adverse Soil Conditions:stable: low soil stressesunstable: shifting soil conditions, significant pipe motion relative to soil

• Mechanical Resistance Heatshrinkable Coating:medium (B): moderate impact and penetration resistancehigh (C): high impact and penetration resistance

• Pipe Laying Method:f.i.. Open Trench, Directional Drilling, Off-Shore

• Climate conditions (Ambient Temperature during Sleeve Application):sea climate: not very cold - not very warmland climate: very cold - warmdesert climate: very cold - hot

All of the above parameters affect the type of coating which will providethe best performance, ease of installation and value. The following selec-tion tables will help you to decide which sleeve is right for your applica-tion.

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4Girth weld straight joints –Selection table for Heat Shrinkable Products

By checking the appropriate parameters, you can easily select the proper product

Max Pipe Compatible Recomm. Soil Pipelaying Recommend. Mechanical Climate Coating Adhesive ProductOperating Pipe Pipe Conditions Method Pipe Resistance Conditions LayersTemp. Line Coating Diameter Preparation Class°C / °F Type

TUBULAR PRODUCTS

30 / 86 Bitumen, 2" – 12" Stable Open Brushing Medium (B) SEA 2 /11 TPSCTE, CAT, trench Low PreheatFBE, PE

30 / 86 Bitumen, 1" – 8" Stable Open Brushing High (C) SEA 2 /236 TPSM-C30CTE, CAT, trench Low PreheatFBE, PE

50 / 122 Bitumen, 1" – 8" Stable Open Brushing Medium (B) SEA & 2 /87 TPSM/87CTE, CAT, trench Low Preheat LANDFBE, PE

WRAPAROUND PRODUCTS

30 / 86 Bitumen, 3" – 20" Stable Open Brushing Medium (B) SEA 2 /11 WPCTCTE, CAT, trench Low PreheatFBE, PE

30 / 86 Bitumen, 3" – 20" Stable Open Brushing Medium (B) SEA 2 /236 WPC-B/C30CTE, CAT, trench Low Preheat & High (C)FBE, PE

50 / 122 CTE, CAT, > 3" Stable & Open Gritblasting Medium (B) SEA & 2 /165 WPC-B/C50FBE, PE Unstable trench High Preheat & High (C) LAND

60 / 140 CTE, CAT, 3" – 20" Stable Open Brushing Medium (B) SEA & 2 /160 WPC65MFBE, PE, PP* trench Low Preheat LAND

65 / 149 Bitumen, > 3" Stable & Open Gritblasting Medium (B) SEA & 3 /106 HTLP60CTE, CAT, Unstable trench Low Preheat & High (C) LAND (extraFBE, PE, PP** epoxy layer)

80 - 100 Bitumen, > 3" Stable & Open Brushing Medium (B) SEA & 2 /159 WPC100M176 - 244 CTE, CAT, Unstable trench / High Preheat LANDfor offshore FBE, PE, PP Offshoreapplications

80 / 176 CTE, CAT, > 3" Stable & Open Gritblasting Medium (B) SEA & 3 /202 HTLP80FBE, PE Unstable trench / Low Preheat & High (C) LAND & (extra

Offshore DESERT epoxy layer)

120 / 248 CTE, FBE, > 3" Stable & Open Gritblasting Medium (B) SEA & 2 /193 WPC120PE Unstable trench Very High LAND &

Preheat DESERT

SPECIAL APPLICATIONS

50 / 122 Bitumen, > 3" NA*** Offshore Brushing NA*** (extra NA 2 /11 WPCZCTE, CAT, (offshore) Low Preheat outside (offshore)FBE, PE coating)

60 / 140 FBE, PE > 3" Stable & Directional Gritblasting High (C) SEA & 3 /183 DIRAXUnstable Drilling Low Preheat LAND (extra ROCS60E

epoxy layer)

* For application on PolyPropylene line coating, only suitable for 30°C (86°F) operating temperature.** No epoxy on PP coating.*** NA = not applicable

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4Product description

TPSM heat-shrinkable tubes are compatible with standard pipe coatings includ-ing PE, FBE, tape and coal tar.

The comprehensive range of sizes allows all pipe diameters upto DN 200 mm(8 inches) to be covered.

From nominal pipe size DN 200 and larger, we recommend the heat-shrinkablewraparound sleeve WPC or HTLP.

Ordering information

• Installation is carried out directly on the cleaned and dried (pre-heated) pipesurface. No primer is required to promote adhesion

• Compatible with standard commercial mill-applied coatings

• In the event of mechanical damage, the sealing adhesive flows and seals offthe damaged area (self-healing effect)

• No special tools needed, leading to low installation costs

• Continuous, tubular design means no closure patch is necessary (tubes mustbe slided over the pipe prior to welding the joint)

• The thick-walled structure of the crosslinked heat-shrinkable material gives ithigh impact strength and penetration resistance (TPSM-C30)

Product features/benefits

Selection table Pipe Pipe TPS TPSM-C30diameter size order description order descriptionDN in inch

25 1.250 NA TPSM-C30-DN25-370

40 1.875 NA TPSM-C30-DN40-370

50 2.375 TPS 2375x18 TPSM-C30-DN50-37060 2.875 TPS 2875x18 NA

80 3.500 TPS 3500x18 TPSM-C30-DN80-370

90 4.000 TPS 4000x18 NA100 4.500 TPS 4500x18 TPSM-C30-DN100-370

125 5.563 TPS 5563x18 TPSM-C30-DN125-500

150 6.625 TPS 6625x18 TPSM-C30-DN150-500200 8.625 TPS 8625x18 TPSM-C30-DN200-600

250 10.750 TPS 10750x18 NA (use WPC C30)

300 12.750 TPS 12750x18 NA (use WPC C30)

350 14.000 TPS 14000x18 NA (use WPC C30)400 16.000 TPS 16000x18 NA (use WPC C30)

450 18.000 TPS 18000x18 NA (use WPC C30)

500 20.000 TPS 20000x18 NA (use WPC C30)

For ordering see ordering description in table below.

Standard version suitable for commonly pipe diameter used cutbacks:• up to 100 mm (4 inches) for each pipe end (DN 25–50 or 1–2 inches)• up to 150 mm (6 inches) for each pipe end pipe diameter (larger than DN50

or 2 inches)

1. Tubular productTPS, TPSM-C30

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4Installation procedure 1. Slide the heat-shrinkable sleeve,

complete with its protective foil, ontothe pipe before the joint is made.

NoteThe sleeve is correctly installed when:– The complete sleeve is in contact

with the surface of the pipe, it issmooth and has no cold-spots or airenclosures.

– adhesive flow is evident at bothsleeve edges along the circumfer-ence of the pipe.

– the overlap on the mill-applied coat-ing is as specified.

2. Prepare the pipe surface that is tobe coated, according to SIS-055900-ST3 or SIS-055900-SA 2 1/2.

No primer is required.

3. Using a propane torch, pre-heat thesurface to about +60°C (140°F).

4. Position the sleeve over the weldedjoint so that it overlaps the mill-appliedcoating by at least 50 mm (2 inches).

Remove the release foil.

5. Working from the centre outwards,heat the sleeve with a soft yellow pro-pane flame, keeping the torch insteady circumferential motion.

For appropriate installation,please consult the correspondinginstallation instruction.

1. Tubular productTPS, TPSM-C30

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WPCT, WPC/B, WPC B30, WPC C30 sleeves are heat-shrinkable ready-to-fitassemblies for the corrosion protection of welded joints. They are compatiblewith standard pipe coatings – including PE, CTE, CT, FBE, PP and asphalt-based coatings.

WPCZ is a thinner two-layer system, used only for corrosion protection ofwelded joints under heated infill systems in offshore networks.

WPC B30, WPC C30, WPCT products should normally not be used in highsoil stress environments or on buried pipelines with diameters greater than500 mm (20 inches).

Designates pre-attached closure for the UNISLEEVEconstruction; in case of ordering cut pieces,drop the ‘/UNI’ code.

11, 17, 24, 34 standard width (W) as delivered: 11 (285 mm or11.25 inches), 17 (450 mm or 17.75 inches),24 (600 mm or 23.50 inches) and 34 (870 mm or 34.25 inches)

see applic. table outside pipe diameter30 continuous operating temperature up to 30°C (86°F) in case of a WPC

B30, WPC C30, 50°C (122°F) in case of a WPCZB, C performance classification: B for WPC B30, C for WPC C30T, Z product type: T for WPCT, Z for WPCZ


• These products are available on rolls or as Unisleeves

• Installation is carried out directly on the cleaned and dried (pre-heated) pipesurface. No primer is required

• No special tools are needed – leading to low installation costs

• The thick-walled structure of the cross-linked heat-shrinkable sleeve gives thematerial high impact strength and high penetration resistance (WPC C30)

• Compatible with standard mill-applied coatings

• In the event of mechanical damage the sealing adhesive fills and seals off thedamaged area (“self-healing” effect)

• WPCZ sleeves permit rapid, reliable installation on weight-coated pipelinesdelivered from lay barges or reel ships


WPC type products are available: • as Unisleeve (sleeve and patch are one set)• as a roll (patch is ordered seperately)

66, 100 standard roll length (L): 100 feet (30 m), otherpossible roll length: 66 feet (20 m) for 34 inches width

11, 17, 24, 34 standard width (W) as delivered30 continuous operating temperature up to 30°C (86°F):

for WPC B30, WPC C30, 50°C (122°F) in case of WPCZB, C performance classification: B for WPC B30, C for WPC C30T, Z product type: T for WPCT, Z for WPCZ

11, 17, 24, 34 nominal closure length (L)3, 4, 5, 6, 8 nominal closure width (W): 3 (75 mm or 3 inches), 4 (100 mm

or 4 inches), 5 (125 mm or 5 inches), 6 (150 mm or 6 inches), 8 (200 mmor 8 inches)

Application table for rolls

WPCX-(YZZ)-AAAA x BB /UNI

WPCX-YZZ-BB x CCC

WPCP IV-X x YY

L L

42. Two-layer coating for pipes with ambient operating temperature

WPCT, WPC/B, WPC B30, WPC C30, WPCZ

Unisleeve

RollRoll

Closure patch

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Installation procedure

2. Using a propane torch, pre-heat thesurface to about +60°C (140°F).

NoteThe sleeve is correctly installed when:– The complete sleeve is in contact with the surface of the pipe, it is smooth

and has no cold-spots or air enclosures.– adhesive flow is evident at both sleeve edges along the circumference of the

pipe.– the overlap on the mill-applied coating is as specified.– Where a pipe has exceptionally large weld-beads, or the step-down from the

pipe coating to bare steel is particularly large, the use of a mastic filler strip isrecommended. The strip fills the fillet area, which could entrap air duringshrink sleeve installation.

3. Take the ready-to-fit wraparoundsleeve. Cut corners (15 mm x 50 mmor 0.6 x 2 inches) at one sleeve end.Remove the release foil to about150 mm (6 inches) from the end withthe cut-off corners. Place the sleeveend centrally over the weld area at aright angle to the axis of the pipe. TheWPC sleeve should overlap the mill-applied coating for at least 50 mm(2 inches) on both edges. Wrap thesleeve around the pipe so that it over-laps the sleeve edge by 50 to 150 mm(2 to 6 inches) (a function of pipe diam-eter), at the same time removing therest of the release foil.

5. Using a medium flame with yellowtip and keeping it constantly on themove, uniformly heat the closurepatch until the fiberglass weave showsthrough. With a gloved hand, smooththe closure patch firmly down, elimi-nating wrinkles, to achieve the bestpossible contact with the sleeve.

6. Then shrink the sleeve with a longflame with yellow tip, beginning at theside opposite to the direction of thewind, moving the torch continuously ina paintbrush motion all around thesleeve. WPCZ is used for girthweldprotection on weight-coated pipes.

1. Prepare the pipe surface that is tobe coated, according to SIS-055900-ST3 or SIS-055900-SA 2 1/2.


4. The overlap should be on the upperthird of the pipe, where it is readily ac-cessible. In low ambient temperaturesit is advisable to briefly warm the in-side of the overlapping ends and alsothe closure patch.


42. Two-layer coating for pipes with ambient operating temperature

WPCT, WPC/B, WPC B30, WPC C30, WPCZ

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Product description

WPC B50, WPC C50, WPC65M, WPC100M and WPC120 sleeves are espe-cially suitable for higher stress conditions caused both by elevated tempera-tures and by soils with severe contraction between wet-dry cycles.

These products are based on a two-layer system and are normally used forPE-coated steel pipe, and may be used for girth-weld protection or to recoat(rehabilitate) long pipe sections and large radius bends.


• The wraparound pipe sleeve for field girth weld corrosion protection (WPC) isa heat-shrinkable wraparound sleeve, closed with a patch closure that may besupplied separately or preattached to one sleeve end. The WPC sleeves areavailable with different constructions and adhesives

• Wide range of operating temperature ratings

• Higher shear resistance than ambient temperature sleeves

• Simple installation requiring only a torch and a roller


WPC type products are available: • as cutpiece (precut sleeve and patch)• as Unisleeve (sleeve with preattached patch)• as a roll (patch is ordered seperately)

Designates pre-attached closure for the UNISLEEVEconstruction; in case of ordering cut pieces,drop the ‘/UNI’ code.

11, 17, 24, 34 standard width (W) as delivered: 11 (285 mm or11.25 inches), 17 (450 mm or 17.75 inches),24 (600 mm or 23.50 inches) and 34 (870 mm or 34.25 inches)

see applic. table outside pipe diameter50 continuous operating temperature up to 50°C (122°F)

in case of a WPC B50, WPC C50B, C performance classification: B for WPC B50, C for WPC C50100M, 120 product type: 65M for WPC65M, 100M for WPC100M, 120 for WPC120

66, 100 standard roll length (L): 100 feet (30 m), otherpossible roll length: 66 feet (20 m) for 34.2 inches width

11, 17, 24, 34 standard width (W) as delivered50 continuous operating temperature up to 50°C (122°F):

50 for WPC B50, WPC C50 productB, C performance classification: B for WPC B50, C for WPC C50100M, 120 product type: 65M for WPC65M, 100M for WPC100M, 120 for WPC120

WPCP IV-XX x YY11, 17, 24, 34 nominal closure length (L)3, 4, 5, 6, 8 nominal closure width (W): 3 (75 mm or 3 inches),

4 (100 mm or 4 inches), 5 (125 mm or 5 inches),6 (150 mm or 6 inches), 8 (200 mm or 8 inches)

WPCX-YZZ-AAAA x BB /UNI

WPCX-YZZ-BB x CCC

Application table

L L

Unisleeve

RollRoll

Closure patch

Product Operating temperatureWPC B50/C50 50°C (122°F)WPC65M 65°C (149°F)WPC100M 80°C (176°F) (onshore)

100°C (212°F) (offshore)WPC120 120°C (248°F)

43. Two-layer coating for pipes with elevated operating temperature

WPC B50, WPC C50, WPC65M, WPC100M, WPC120

GIRTH WELD COATING

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2. Using a propane torch, pre-heat thesurface according the correspondingtemperature:

3. Take the ready-to-fit wraparoundsleeve. Cut corners (15 mm x 50 mmor 0.6 x 2 inches) at one sleeve end.Remove the release foil to about150 mm (6 inches) from the end withthe cut-off corners. Place the sleeveend centrally over the weld area at aright angle to the axis of the pipe. TheWPC sleeve should overlap the mill-applied coating by at least 50 mm(2 inches) on both edges. Wrap thesleeve around the pipe so that it over-laps the sleeve edge by 50 mm(2 inches), at the same time removingthe rest of the release foil.

5. Using a medium flame with yellowtip and keeping it constantly on themove, uniformly heat the closurepatch until the fiberglass weave showsthrough. With a gloved hand, smooththe closure patch firmly down, elimi-nating wrinkles, to achieve the bestpossible contact with the sleeve.

6. Then shrink the sleeve with a longflame with yellow tip, beginning at theside opposite to the direction of thewind, moving the torch continuously ina paintbrush motion all around thesleeve.

1. Recommended surface preparationis SIS-055900-ST3 or SIS-055900-SA 2 1/2 and PE abrading.


Note: for WPC120 recommended sur-face preparation is SIS-055900-SA 2 1/2.

4. The overlap should be at the upperthird of the pipe, where it is readily ac-cessible. In low ambient temperaturesit is advisable to briefly warm the in-side of the overlapping ends andshortly also the closure patch.

WPC B50,C50 70°C (158°F)WPC65M 60°C (140°F)WPC100M 100°C (212°F)WPC120 230°C (446°F)


NoteThe sleeve is correctly installed when:– The complete sleeve is in contact with the surface of the pipe, it is smooth

and has no cold-spots or air enclosures.– adhesive flow is evident at both sleeve edges along the circumference of the

pipe.– the overlap on the mill-applied coating is as specified.– Where a pipe has exceptionally large weld-beads, or the step-down from the

pipe coating to bare steel is particularly large, the use of a mastic filler strip isrecommended. The strip fills the fillet area, which could entrap air duringshrink sleeve installation.

43. Two-layer coating for pipes with elevated operating temperature

WPC B50, WPC C50, WPC65M, WPC100M, WPC120

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Product description

Raychem’s three-layer field-joint coatings (HTLP) are the toughest field appliedcoating systems available. The three-layers: epoxy, copolymer and modifiedcross-linked polyethylene are designed to replicate the structure and meet theperformance of mill-applied three-layer PE coatings. The coatings are compat-ible with all commonly used pipe coatings including PE, coal tar enamel, coal tarepoxy, and fusion-bonded epoxy. The system is designed to be applied withminimum preheating of the pipe.

The HTLP system consists of a solvent-free two-component liquid epoxy and awraparound heat-shrinkable sleeve. During installation, the epoxy is applied tothe prepared pipe surface and the heat-shrinkable sleeve is immediatelywrapped around the joint and shrunk. While curing, the epoxy forms a strongmechanical bond to the pipe surface and a strong chemical bond to the shrinksleeve’s adhesive layer. The radiation-cross-linked outer layer forms a durablebarrier to moisture and mechanical damage.

HTLP60 and HTLP80 can alsobe installed without epoxy.

Application table

L L

L L

B, 1–1.5 thickness: B (1 mm (0.04 inch) backing / 1 mm (0.04 inch) coating),1–1.5 (1 mm (0.04 inch) backing /1.5 mm (0.06 inch) coating)

66, 100 standard roll length (L): 100 feet (30 m), other possibleroll length: 66 feet (20 m) for 34.2 inches width

see applic. table roll width (W)60, 80 sleeve type/WPC /WPC: to indicate this coated sheet can be used

as a 2-layer system without epoxy primer

WPCP IV-X x YY11, 17, 24, 34 nominal closure length (L)3, 4, 5, 6, 8 nominal closure width (W): 3 (75 mm or 3 inches),

4 (100 mm or 4 inches), 5 (125 mm or 5 inches),6 (150 mm or 6 inches), 8 (200 mm or 8 inches)

HTLP/WPC XX-YY x ZZZ/T-RLRoll

Closure patch

Roll

Epoxy primer HTLP60 is installed with S1239 or S1301 epoxy primer.HTLP80 is installed with S1301 epoxy primer.For more ordering information on epoxy primers.

Closure patch preattachedB, 1–1.5 thickness: B (1 mm (0.04 inch) backing / 1 mm (0.04 inch) coating),

1–1.5 (1 mm (0.04 inch) backing /1.5 mm (0.06 inch) coating)11, 17, 20, 24, 34 standard width (W) in inches as delivered: 11 (285 mm

or 11.25 inches), 17 (450 mm or 17.75 inches),20 (514 mm or 20.25 inches), 24 (600 mm or23.50 inches) and 34 (870 mm or 34.25 inches)

see applic. table outside pipe diameter60, 80 sleeve type (60 or 80)

HTLP XX-YYYY x ZZ/T/UNIUnisleeve

Ordering information HTLP type products are available: • as cutpiece (precut sleeve and patch)• as Unisleeve (sleeve with preattached patch)• as a roll (patch is delivered seperately)

• Fully resistant to shear forces induced by soil and thermal movements

• Sleeve applied over wet epoxy, with no curing or waiting times

• Superior cathodic disbondment performance and hot water immersionresistance

• Fully reconstructs three-layer coating at all girth welds for continuous andhomogeneous performance on pipelines coated with 3LPE

• Low preheat requirements


44. Three-layer coated systems for pipes with ambient and elevated

operating temperature HTLP60, HTLP80

GIRTH WELD COATING

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Installation procedure 1. Recommended surface preparationis SIS-055900-SA 2 1/2. Also abradeor sweep blast adjacent pipe coating.

2. Pre-heat the surface to min 70°C –max 100°C (min 158°F – max 212°F)and apply the prepared and thor-oughly mixed two-component epoxyresin on the steel area and the adja-cent line coating to be covered withthe sleeve.

3. Place the sleeve end centrally overthe weld area at a right angle to theaxis of the pipe. The HTLP sleeveshould overlap the mill-applied coatingby at least 50 mm (2 inches) on bothedges. Wrap the sleeve with its clo-sure patch, around the pipe. Ensurethat the leading sleeve edge overlapsthe other edge by 50 mm (2 inches).

4. Next, using a medium flame withyellow tip and keeping it constantlymoving in a paintbrush motion, uni-formly heat the closure patch until thefiberglass weave shows through. Witha gloved hand, smooth the closurepatch firmly down, free from wrinkles.Roll out the closure area with a sili-cone roller.

5. Finally, shrink the sleeve with a longflame with yellow tip, beginning at theside opposite to the direction of thewind, moving the torch continuously ina paintbrush motion all around thesleeve.


NoteThe sleeve is correctly installed when:– The complete sleeve is in contact


– adhesive flow is evident at bothsleeve edges along the circumference of the pipe.

– the overlap on the mill-applied coat-ing is as specified.

– Where a pipe has exceptionallylarge weld-beads, or the step-downfrom the pipe coating to bare steel isparticularly large, the use of a masticfiller strip is recommended. The stripfills the fillet area, which could entrapair during shrink sleeve installation.

44. Three-layer coated systems for pipes with ambient and elevated

operating temperature HTLP60, HTLP80


The sleeve is used for corrosion protection of girth welds on coated pipes usedfor horizontal or directional drilling.

The DIRAX kit consists of:– A two part epoxy primer– A wraparound, fiberglass-reinforced, heat-shrinkable sleeve with a pre-

attached closure and a coating of high shear thermoplastic adhesive– A second, narrower, wraparound fiberglass reinforced ‘leading edge’ heat-

shrinkable sleeve

5. Three-layer coating for horizontal or directional drillingapplications DIRAX

• Extremely high shear and peel strength

• Excellent abrasion resistance

• Short ready time. Sleeve is installed on top of wet epoxy. Pulls may be madeas soon as sleeve is cool

• Superior cathodic disbondment performance

• Simple installation without special tools



see applic. table z units of epoxy resin S1239-Primer-Kit-252(separate ordering and delivery required by shipping regulations)

12, 17, 24, 34 standard width as delivered: 12 (300 mm or 11.80 inches),17 (430 mm or 17 inches), 24 (600 mm or 23.50 inches),34 (870 mm or 34.25 inches)

see applic. table outside pipe diameter

DIRAX-XXXXX-YY/zK

Epoxy primer

Application table

GIRTH WELD COATING

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Installation procedure 1. Recommended surface preparationis SIS-055900-SA 2 1/2 and PEabrading.

NoteThe sleeve is correctly installed when:- the complete sleeve is in contact


- adhesive flow is evident at bothsleeve edges along the circumfer-ence of the pipe.

- the overlap on the mill-applied coat-ing is as specified.

2. Pre-heat the surface to min. 70°C(158°F) and apply the prepared andproperly mixed two-component epoxyresin “only” on the steel area.

3. Take the ready-to-fit wraparoundsleeve and remove the release plasticabout 150 mm (6 inches) from the endwith the cutoff corners. Place thesleeve end centrally over the weldarea at a right angle to the axis of thepipe. The DIRAX sleeve should over-lap the mill-applied coating by at least50 mm (2 inches) on both edges.Wrap the sleeve, with its integratedclosure patch, around the pipe ensur-ing that the leading sleeve edge over-laps the other edge by 50 mm(2 inches), at the same time removingthe rest of the release foil.

4. Next, using a medium flame withyellow tip and keeping it constantlymoving in a paintbrush motion, uni-formly heat the closure patch until thefiberglass weave shows through. Witha gloved hand, smooth the closurepatch firmly down, free from wrinkles.Roll out the closure area with a sili-cone roller. Then shrink on the sleevewith a long flame with yellow tip, be-ginning at the leading edge and mov-ing the torch continuously in a paint-brush motion all around the sleeve.

5. Position the narrow heat-shrinkablestrip centrally over the leading edge ofthe sleeve. Make sure the closurepatch of narrow strip does not overlapthe patch of main sleeve. Shrink it inthe same way as the sleeve. CheckPE temperature prior to shrinking.

Roll out the front-end sleeve all roundusing a silicone roller.


45. Three-layer coating for horizontal or directional drilling

applications DIRAX

GIRTH WELD COATING

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DIRAX

Selection of sleeve width Minimum installed overlap onto the line coating shall be 50 mm (2 inches). Inorder to allow for some width shrinkage during installation, please add a 10%safety factor, to the calculated width, and then choose the next widest standardwidth available e.g.:

For a 150 mm (6 inches) maximum cutback of coating at each pipe end, and aminimum specific 50 mm (2 inches) overlap of sleeve onto line coating, thecalculated width will be 2 (150 + 50) x 1,1 = 440 mm (17.32 inches) and thestandard (supplied) width will be 450 mm (17.75 inches).

For a 150 mm (6 inches) maximum cutback of coating at each pipe end, butwith a minimum specified 75 mm installed overlap of sleeve onto line coating,the calculated width will be 2 (150 + 75) x 1,1 = 495 mm (19.5 inches) and thestandard supplied width will be 500 mm (20 inches).

2 (maximum cutback + minimum overlap) x 1,1

Pipe Outside Optional metal belt Epoxy primer kitdiameter pipe diameter cut length nominal S1239-primer-kit-252 or S1301-primer-15-kitDN inch mm inch mm inch W = 34 inch W = 24 inch W = 17 inch W = 12 inch

W = 850 mm W = 600 mm W = 450 mm W = 300 mm80 3 88,9 3.500 595 23.4 1 1 1 1

100 4 114,3 4.500 680 26.7 1 1 1 1125 5 141,3 5.563 760 29.9 1 1 1 1150 6 168,3 6.625 850 33.5 1 1 1 1200 8 219,1 8.625 1005 39.6 1 1 1 1250 10 273,1 10.750 1175 46.3 1 1 1 1300 12 323,9 12.750 1330 52.4 1 1 1 1350 14 355,6 14.000 1450 57.1 1 1 1 1400 16 406,4 16.000 1605 63.2 1 1 1 1450 18 457,2 18.000 1765 69.5 1 1 1 1500 20 508,0 20.000 1925 75.8 2 1 1 1550 22 558,8 22.000 2085 82.1 2 1 1 1600 24 609,6 24.000 2245 88.4 2 2 1 1650 26 660,4 26.000 2405 94.7 2 2 1 1700 28 711,2 28.000 2565 100.9 2 2 1 1750 30 762,0 30.000 2725 107.3 2 2 1 1800 32 812,8 32.000 2825 111.2 2 2 1 1850 34 863,6 34.000 2985 117.5 2 2 1 1900 36 914,4 36.000 3135 123.4 2 2 1 1

1000 40 1016,0 40.000 3450 135.8 2 2 2 11050 42 1066,8 42.000 3740 147.2 3 3 2 11100 44 1120,0 44.000 3900 153.5 3 3 2 11150 46 1170,8 46.000 4060 159.8 3 3 2 11200 48 1220,0 48.000 4220 166.1 3 3 2 11250 50 1270,0 50.000 4400 173.2 4 3 2 11300 52 1320,8 52.000 4580 180.3 4 3 2 21350 54 1371,6 54.000 4750 187.0 4 3 2 21400 56 1422,0 56.000 4900 192.9 4 3 2 21450 58 1473,2 58.000 5070 199.6 4 3 2 21500 60 1524,0 60.000 5230 205.9 4 3 2 2

Notes: 24 inches nominal for joint cutbacks up to 16 inches (400 mm) maximum 12 inches is recommended forFBE coated pipes with cutbacks of 6 inches (150 mm)

W = sleeve width

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Pipe Outsidediameter pipe diameterDN inch mm inch mm inch mm inch inch mm inch mm

WPCT WPCT WPC120 WPC120 WPCT WPC C30WPC/B WPC/B WPCZ WPC C50WPCZ WPCZ WPC B30WPC B30 WPC B30 WPC B50WPC C30 WPC C30 WPC 65MWPC B50 WPC B50 WPC100MWPC C50 WPC C50 WPC120WPC65M WPC65M HTLP60WPC100M WPC100M HTLP80HTLP60 HTLP60HTLP80 HTLP80

50 2 57,1 2.375 305 12.0 3 80 NA65 2 1/2 66,7 2.875 330 13.0 3 80 NA80 3 88,9 3.500 380 15.0 380 15 4 100 5 125

100 4 114,3 4.500 460 18.0 485 19 4 100 5 125125 5 141,3 5.563 550 21.5 585 23 4 100 5 125150 6 168,3 6.625 640 25.0 685 27 4 100 5 125200 8 219,1 8.625 800 31.5 915 36 4 100 5 125250 10 273,1 10.750 980 38.5 1115 44 4 100 5 125300 12 323,9 12.750 1150 45.5 1265 50 4 100 6 150350 14 355,6 14.000 1260 49.5 1395 55 4 100 6 150400 16 406,4 16.000 1420 56.0 1575 62 4 100 6 150450 18 457,2 18.000 1590 62.5 1730 68 4 100 6 150500 20 508,0 20.000 1770 69.5 1900 75 6 150 8 200550 22 558,8 22.000 1950 77.0 2055 81 6 150 8 200600 24 609,6 24.000 2110 83.0 2205 87 6 150 8 200650 26 660,4 26.000 2270 89.5 2415 95 6 150 8 200700 28 711,2 28.000 2430 95.5 2590 102 6 150 8 200750 30 762,0 30.000 2600 102.5 2720 107 6 150 8 200800 32 812,8 32.000 2760 108.5 2895 114 6 150 8 200850 34 863,6 34.000 2930 115.5 3075 121 6 150 8 200900 36 914,4 36.000 3100 122.0 3225 127 6 150 8 200950 38 965,2 38.000 3260 128.5 3400 134 6 150 8 200

1000 40 1016,0 40.000 3430 135.0 3555 140 6 150 8 2001050 42 1066,8 42.000 3590 141.5 3735 147 6 150 8 2001100 44 1120,0 44.000 3750 147.5 3890 153 6 150 8 2001150 46 1170,8 46.000 3910 154 4065 160 6 150 8 2001200 48 1220,0 48.000 4065 160 4215 166 6 150 8 2001250 50 1270,0 50.000 4240 167 4420 174 6 150 8 2001300 52 1320,8 52.000 4420 174 4570 180 6 150 8 2001350 54 1371,6 54.000 4590 180.5 4750 187 6 150 8 2001400 56 1422,0 56.000 4750 187 4930 194 6 150 8 2001450 58 1473,2 58.000 4920 193.5 5105 201 6 150 8 2001500 60 1524,0 60.000 5080 200 5310 209 6 150 8 200

WPCT, WPC/B, WPC B30, WPC C30, WPCZ, WPC B50, WPC C50, WPC65M, WPC100M,WPC120, HTLP60, HTLP80

Sleeve length Patch width


GIRTH WELD COATING

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Pipe coating5

• Extremely high shear resistance provides the strength required to soil-anchorhot pipelines

• Ease of installation. Rayclad is supplied as a complete coating ready to install

• May be transported with minimum damage, and resists backfill compactionand soil stresses without a rock shield

• Wide handling and operating temperature range. Rayclad may be handled attemperatures down to –40°C (–40°F); and comes in formulations available forpipelines operating to 80°C (176°F) and 120°C (248°F)

• Rayclad may be stored without shelf-life or gel-time limitations

• Highly resistant to U.V. light, fungus and cathodic disbondment


Product description

Rayclad hot-applied product coatings are designed to provide a continuous,holiday-free, permanent barrier which affords long-term protection for high-temperature pipelines operating both on- and offshore. Rayclad coatings consistof a thick, radiation cross-linked polyethylene based backing coated with a highshear strength, thermoplastic copolymer adhesive. The coatings, available informulations for pipelines operating up to 120°C (248°F), are supplied in vari-ous widths to accommodate different pipe diameters. The products are installedby professional pipe coaters in their factories, or may be applied nearer thepipeline construction site using Raychem’s portable pipe coating equipment.

Product thickness Standard roll width Standard roll lengthas supplied(inches) (mm) (inches) (mm) (feet) (m)

RAYCLAD /A 0.050 1.27 3, 4, 6, 9, and 11 75, 100, 150, 225 and 275 500 152

RAYCLAD /B 0.075 1.90 3, 4, 6, 9, and 11 75, 100, 150, 225 and 275 400 122

Rayclad Dimensions

Two-layer pipe coating for elevated temperatureRAYCLAD

Recommended productwidth versus pipe diameter

Rayclad's are designed to be applied as line coating on bare steel pipes to coatthe entire pipe circumference. Type / A construction is normally used for pipessmaller than 20 inch diameter and type / B is recommended for maximum me-chanical protection and for all pipe sizes – especially for pipes of 20 inch orlarger diameter. Type / B is not normally used for pipes smaller than 6 inch dia-meter (due to stiffness).1. Type / A is used for seamless or spiral welded pipes2. Type / B is used for seamless pipes

Recommended Raycladconstrucion versus pipedimensions

Product width Pipe diameter(inches) (mm) (inches) (DN)

3 75 < 4.500 < 1004 100 4.500 to 5.563 100 - 1256 150 6.625 to 8.625 150 - 2009 225 10.750 to 14.000 250 - 350

11 275 > 14.000 > 350

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RAYCLAD XX-YY x ZZZ/T-RL

Installation Instruction

/A, /B type500, 400 roll length (feet)3, 4, 6, 9, 11 roll width (inches)80, 120 Rayclad type

For detailed installation instructions ask for the “Rayclad Coating Manual” .

The Raychem deployable coating plant requires:

Power supply: 50-200 kW220 V, 380 V, 440 V or 480 Vthree phase50/60 Hz

Compressed air: 6–7 bar (90–105 psi)

NG or propane: 1.5–2.5 bar (22–36 psi)

Gas flow: 135 kg/hour (NG) or 100 kg/hour (propane)

Water cooling: 3–4 bar (45–60 psi); +10°C to +25°C(+50°F to +75°F)

Max. water consumption: 6–10 m3/hr (1,580–2,640 gallons/hr)

Before pipe is either shot or gritblasted, all dirt, loose corrosion or other foreignmaterial must be removed by wire brush or other means.

Pipe should be preheated to approximately 35oC to 40oC (95°F to 104°F) beforeshot- or gritblasting to dry the pipe and remove moisture.

Normal practice for obtaining the desired cleaning level, SA 2.5, Ra max. 50µprofile, is to use a high speed wheels shot blast equipment, using a combinationof steel shot and grit to produce the desired surface. Conventional air operatedsand blast equipment will produce an acceptable cleaning level using the appro-priate mesh cleaning media to meet the profile requirements. It should be notedthat sand blasting will give a much lower rate of cleaning compared to shot/gritblasting.

Pipe surface must be clean from dust and must be inspected for steel sliver,other type of defects or contamination that could effect coating quality.

Blasted and cleaned pipe shall be coated within 6 hours after cleaning. If at anytime surface rust develops, pipe must be blasted again.

Pipe surface preparation

5Two-layer pipe coating for elevated temperatureRAYCLAD

PIPE COATING

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Pipe size

Pipe X Outside pipe X Area of pipe Recommended product width

DN inch mm inch ft 2/mile m2/km inch mm50 2 57,1 2.375 3,297 190.4 3 7565 2 1/2 66,7 2.875 3,981 229.9 3 7580 3 88,9 3.500 4,838 279.3 3 75

101,6 4.000 5,529 319.2 3 75100 4 114,3 4.500 6,220 359.1 4 100

127,0 5.000 6,912 399.1 4 100125 5 141,3 5.563 7,699 444.5 4 100150 6 168,3 6.625 9,165 529.2 6 150

193,7 7.625 10,546 603.7 6 150200 8 219,1 8.625 11,929 688.8 6 150250 10 273,1 10.750 14,860 858.0 9 230300 12 323,9 12.750 17,624 1017.6 9 230350 14 355,6 14.000 19,353 1117.4 9 230400 16 406,4 16.000 22,117 1277.0 11 280450 18 457,2 18.000 24,881 1436.6 11 280500 20 508,0 20.000 27,646 1596.3 11 280550 22 558,8 22.000 30,410 1755.8 11 280600 24 609,6 24.000 33,175 1915.5 11 280650 26 660,4 26.000 35,940 2075.1 11 280700 28 711,2 28.000 38,704 2234.7 11 280750 30 762,0 30.000 41,469 2394.4 11 280800 32 812,8 32.000 44,234 2554.0 11 280850 34 863,6 34.000 46,998 2713.6 11 280900 36 914,4 36.000 49,763 2873.3 11 280950 38 965,2 38.000 52,527 3032.9 11 280

1000 40 1016,0 40.000 55,292 3192.5 11 2801050 42 1066,8 42.000 58,057 3352.2 11 2801100 44 1120,0 44.000 60,821 3511.7 11 2801150 46 1170,8 46.000 63,586 3671.4 11 2801200 48 1220,0 48.000 66,350 3831.0 11 280

5Application table

Notes: Material requirements listed here are based on the recommended tape widths, with a standard one-inch overlap.Figures do not include field contingency allowances. A minimum 3 percent contingency is recommended.

To find material requirements for pipe sizes or tape widths not listed in this table, use this formula to calculate thequantity of tape you need: WxA / W–L

W = product width (inches/mm)A = pipe area (ft2/mm2)

L = overlap (inches/mm)X = diameter

PIPE COATING

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Pipe size

Pipe X ft 2 ft 2 of product m2 of product Lin. ft of product Lin. ft of product Lin. m of productper 100 lin. per mile per km per 100 lin. ft per mile per km

DN inch ft of pipe of pipe of pipe of pipe of pipe of pipe

50 2 94 4,946 283.7 375.5 19,782 3732.965 2 1/2 113 5,972 342.6 462.0 23,886 4507.980 3 157 8,294 475.7 628.3 33,174 6259.2

100 4 157 8,293 481.9 471.3 24,880 4724.5175 9,216 535.6 523.6 27,648 5251.0

125 5 194 10,265 596.6 583.2 30,796 5849.0150 6 208 10,998 633.4 416.6 21,996 4167.1

240 12,655 722.5 479.3 25,310 4753.3200 8 254 13,420 773.2 508.0 26,820 5086.9250 10 317 16,718 963.1 422.2 22,290 4205.7300 12 376 19,830 1142.1 500.7 26,436 4987.3350 14 412 21,772 1254.3 549.8 29,030 5477.3400 16 461 24,328 1402.7 502.7 26,540 5027.6450 18 518 27,369 1578.0 565.5 29,857 5655.500 20 576 30,410 1753.4 628.3 33,175 6284.6550 22 634 33,451 1928.6 691.1 36,492 6912.600 24 691 36,493 2104.0 754.0 39,810 7541.2650 26 749 39,534 2279.3 816.8 43,128 8169.5700 28 806 42,574 2454.7 879.6 46,445 8798.2750 30 864 45,616 2630.1 942.5 49,763 9426.9800 32 922 48,657 2805.4 1005.5 53,081 10055.2850 34 979 51,698 2980.7 1068.1 56,398 10683.5900 36 1037 54,739 3156.1 1131.0 59,716 11312.2950 38 1094 57,780 3331.4 1193.8 63,032 11940.5

1000 40 1152 60,821 3506.7 1256.6 66,350 12568.81050 42 1209 63,863 3682.1 1319.5 69,668 13197.51100 44 1267 66,903 3857.3 1383.2 72,985 13825.41150 46 1325 69,945 4032.8 1445.2 76,303 14454.41200 48 1382 72,985 4208.1 1508.0 79,620 15082.8

5Application table

Notes: Material requirements listed here are based on the recommended tape widths, with a standard one-inch overlap.Figures do not include field contingency allowances. A minimum 3 percent contingency is recommended.

To find material requirements for pipe sizes or tape widths not listed in this table, use this formula to calculate thequantity of tape you need: WxA / W–L

W = product width (inches/mm)A = pipe area (ft2/mm2)

L = overlap (inches/mm)X = diameter

PIPE COATING

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Product description

Flexclad is a hand wrapped heat-shrinkable tape used for corrosion protection,especially on pipe bends and also for straight pipes in distribution networks. Onheating, the tape material shrinks; at the same time the sealing adhesive meltsand is forced into all surface irregularities, forming a homogeneous coating.Flexclad should be applied with a 50% overlap.

Flexclad is available in three mechanical classes:Flexclad (B30), Flexclad II (C30), Flexclad II + Overflex (C50)

Overflex is a thin-walled heat-shrinkable wrapping tape, serving as additionalmechanical protection for Flexclad II (C50).

• No primer is required

• Installation is carried out directly on the cleaned and pre-heated pipe surface

• Compatible with standard commercial mill-applied forms of coating

• Thanks to its high flexibility in the supplied condition the tape can be usedequally well at low temperatures and on pipes of small diameter

• Compatibility with varying pipe diameters minimizes inventory

• No special tools needed, leading to low installation costs

• Self tensioning (heat-shrinkable backing)

Product features / benefits


see applic. table tape length in mm

see applic. table tape width in mmII for Flexclad II

Flexclad X – BBB x CCCCC

Application table

Coating of fittings

The cut length is calculated for (3 D, 90°(185°F)) with an overlap of 50%, a linecoating cutback of 150 mm (6 inches) and a 50 mm (2 inches) overlap on pipecoating. An overlap of 50% means that the total coating thickness is at least twolayers everywhere.When using other overlaps or for another bend radius use the following formula:

Tape usage = Pipe X x 3.14 x L / X

L = length outer radius (LOR) + cutbacks + overlaps on pipe coatingX = effective tape width = tape width – tape overlap cut lengthX = diameter

Nom. pipe size Nom. pipe size Min. pipe X Width UsageDN inches mm mm inches m ft

25 1 33.7 35 1 3/8 3.1 10.232 1 1/4 42.4 35 1 3/8 4.1 13.540 1 1/2 48.3 35 1 3/8 4.8 15.750 2 60.3 35 1 3/8 6.3 20.780 3 88.9 50 2 7.5 24.6

100 4 114.3 50 2 10.6 34.8125 5 139.7 75 3 9.6 31.5150 6 168.3 75 3 12.7 41.7200 8 219.1 100 4 14.5 47.6250 10 273.0 100 4 20.6 67.6300 12 323.9 100 4 27.3 89.6

61. BendsFLEXCLAD

COATING OF FITTINGS

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index

Installation procedure 1. Prepare the surface of the pipe tobe coated, according to SIS-055900-ST3 or SIS-055900-SA 2 1/2.

NoteIf the higher temperature and mechani-cal resistance class C50 is required,the shrinking of the FlexClad II C30must immediately be followed by asecond layer, this time of Overflextape, with a 50% overlap. Position theOverflex centrally over the previouslayer of Flexclad II, work in the oppo-site direction to the Flexclad wrapping,and use closure strips for fixing. Heat-shrinking is carried out exactly as withFlexclad.

2. Using a propane torch, pre-heat thesurface to be coated to about +70°C(158°F)

Remove the protective foil and windthe Flexclad tape tightly around thepipe, beginning on the mill-appliedcoating. After the first complete turn,apply the tape spirally so as to give a50% overlap on each turn. If the bandis to be wrapped with Overflex as asecond layer, an overlap of 10–15 mm(0,4 - 0,6 inch) is sufficient.

3. Wrap the entire bend in this man-ner, paying attention to the minimumoverlap. Flexclad tape should extendabout 50 mm (2 inches) over the mill-applied coating. Secure the end of thetape using the supplied closure strips.

4. Heat the coated pipe bend with asoft yellow propane flame. Workingagainst the wrapping of the Flexcladtape, advance the flame spirallyaround the pipe until the adhesivemelts and is successively squeezedout along the edge of the tape.

5. The surface wrapped with Flexcladmust be smooth and tight, without anyair entrapments. Adhesive flow shouldbe evident at the overlaps around thewhole circumference of the tapeedges.


61.Bends

FLEXCLAD

COATING OF FITTINGS

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index

Product description

CSEM-F is a wraparound sleeve with an extremely high shrink ratio, speciallydeveloped for casing/service-pipe sealing.

The closure system used with this product permits rapid and easy installation.

A separate inner supporting sleeve, with reduced diameter at one end, providesadditional mechanical support and permits a continuous transition.

• No primer is required

• Installation is carried out directly on the cleaned and prepared pipe surface

• The system can also be used when the service pipe is not concentric with thecasing



nominal sleeve width in mm

maximum recovered diameter in mm

minimum delivered diameter in mm

CSEM-F-XXX/YYY-ZZZ

Max Casing X Carrier pipe X CSEM-F CASEALinch inch (US only)

DN100 4.500 DN50 2.375 NA CS4500DN125 5.563 DN60 2.875 NA CS5563DN150 6.625 DN80 3.500 NA CS6625DN200 8.625 DN100 4.500 CSEM-F-280/110-425 CS8625DN250 10.750 DN125 5.563 CSEM-F-280/110-425 CS10750DN300 12.750 DN150 6.625 CSEM-F-380/140-425 CS12000DN350 14.000 DN150 6.625 CSEM-F-380/140-425 CS14000DN400 16.000 DN200 8.625 CSEM-F-540/180-425 CS16000DN450 18.000 DN200 8.625 CSEM-F-540/180-425 CS18000DN500 20.000 DN200 8.625 CSEM-F-540/180-425 CS20000DN550 22.000 DN250 10.750 CSEM-F-600/215-425 CS22000DN600 24.000 DN250 10.750 CSEM-F-760/270-600 CS24000DN700 28.000 DN300 12.750 CSEM-F-760/270-600 CS28000DN800 32.000 DN350 14.000 CSEM-F-880/320-600 CS32000DN900 36.000 DN400 16.000 CSEM-F-1050/370-600 CS36000DN1000 40.000 DN400 16.000 CSEM-F-1050/370-600 CS40000DN1100 44.000 DN450 18.000 CSEM-F-1150/410-600 CS44000DN1200 48.000 DN500 20.000 CSEM-F-1250/470-600 CS48000

Application table

Note: product widths are calculated based on centered carrier pipesstep-down between the two pipes should not exceed 375 mm (14.75 inches)

X = diameter

662. Wraparound sleeve for casings

CSEM-F/CASEAL (US)

COATING OF FITTINGS

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index

1. Prepare the surface that is to becoated, according to SIS-055900-ST3.


2. Using a propane torch, pre-heat thesurface to be coated to about +60°C(140°F).

3. Wrap the cut-to-size supportingsleeve round the casing. Work the in-terlaced fingers down onto the servicepipe and close off with adhesive tape.

For Caseal: supporting sleeve is al-ready integrated into the basic sleeve.

4. Remove the release foil. Taking ac-count of the difference in diameter, po-sition the sleeve so that the contactsurface when installed will be equallydivided between the casing and theservice pipe. Close the sleeve.

5. Using a soft yellow propane flameand keeping the torch in a steady cir-cumferential paintbrush motion, firstshrink the sleeve onto the casing andthen onto the transitional zone as faras the service pipe.

Installation is complete when thesleeve fits snugly and smoothlyaround the pipe and the sealing adhe-sive has been squeezed out at theedges



662. Wraparound sleeve for casings

CSEM-F/CASEAL (US)

COATING OF FITTINGS

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index

663. Wraparound sleeve for flanges

FCWS-F/FLANGESEAL (US)

Product description

Use of fiberglass-reinforced plastic (FCWS-F) gives the sleeve a high degreeof mechanical strength as well as a very high shrink ratio.

The FCWS-F sleeve is capable of accommodating the large diameter differ-ence between flanges and pipes.

• Mechanical strength, high impact strength and high penetration resistancemake it unnecessary to employ rock shielding as additional protection for thepipe.

• No primer is required.

• Installation is carried out directly on the cleaned and prepared pipe surface.

• Compatible with standard commercial mill-applied coatings.

• No special tools needed, leading to low installation costs.

• Simple re-entry.



nominal sleeve width in mm

nominal pipe size (DN)

FCWS-F-DN XXX-YYY

Application table Max. X flange Min. pipe X FCWS-F FLANGESEALmm inch mm inch (US only)

141 5.563 73 2.875 FS5563-24168 6.625 89 3.500 FS6625-24185 7.250 73 2.875 FCWS-F-DN65-300200 7.875 89 3.500 FCWS-F-DN80-300219 8.625 102 4.000 FS8625-24230 9.000 114 4.500 FCWS-F-DN100-300 FS10750-24250 9.875 140 5.563 FCWS-F-DN125-300 FS10750-24285 11.250 168 6.625 FCWS-F-DN150-300 FS12750-24355 14.000 168 6.625 * FS14000-24

Bigger sizesavailable,up to 48000

* Alternative products are MEPS, Heps. Consult Customer Service Center formore detail.X = diameter

COATING OF FITTINGS

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index

1. Prepare the surface that is to becoated, according to SIS-055900-ST3.


Using a propane torch, dry off thesurface to be coated and pre-heat thetwo pipe ends to about +60°C(+140°F).

2. Wrap the corrugated paper – sup-plied with the sleeve – around theflange and fix with closure strips tokeep the bolts free from adhesive.Then remove the release foil from thesleeve.

3. Position the heat-shrinkable sleevecentrally over the flange and close itusing a closure patch or channel(FCWS) or a zipper closure (FCWS-F).

4. Next, using a soft yellow flame andkeeping it constantly moving in a paint-brush motion, uniformly heat the clo-sure patch. With a gloved hand,smooth the closure patch firmly down,free from wrinkles. Then shrink on thesleeve, beginning at the flange andworking from the center outwards,keeping the torch in a paintbrush mo-tion.

5. First, shrink one end of the sleeveonto the pipe. Then shrink the otherend of the sleeve, starting again at theflange, to finish the operation.




663. Wraparound sleeve for flanges


COATING OF FITTINGS

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index

Coating repair

High quality factory pipe coatings can be damaged mechanically during trans-portation, storage and laying of pipes. Raychem’s crosslinked backing in combi-nation with high shear adhesives and mastic fillers offer an economically effec-tive and high quality damage repair system.

Selecting the proper repair method

7

Operating temperature

Pipe coating type

Scratches (small superficial damage)

5

Damage (small but deep damage)

Large damaged areas

1

2

3

4

COATING REPAIR

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index

In the event of extensive damage, the use of a heat-shrinkable sleeve is recom-mended. The sleeve type should be of the same as the field joint coating.

Scratch

Max. operating Compatible Producttemperature line coating80°C (176°F) PE, FBE, CTE Perp meltstick

Damage

Max. operating Compatible Mechanical Producttemperature line coating resistance

50°C (122°F) PE, FBE, CTE high PERP80°C (176°F) PE, FBE, CTE high PERP 80

Large damage

Refer to section “girth weld coating”

1

2

3

4

5

Project specifications and/or local standards must be considered.When specifying a repair system, the following parameters must be considered.

Operating temperature

Pipe coating type

Raychem offers a repair system for pipelines operating from low up to 120°C(248°F) maximum operating temperature.

Raychem’s repair systems are designed for polyethylene coatings, either two-layer or three-layer.

Scratches (smallsuperficial damage)

For scratches in the PE that have not reached the metal pipe, Raychem offers amelt stick which may be used to fill the damaged area completely.

Damage (small butdeep damage)

In case of a failure in the coating which goes down to the metal pipe, Raychemoffers a repair system which consists of a filler mastic and a hotmelt coatedrepair patch. If a three-layer coating is to be repaired, an additional epoxy layercan be applied to the metal.

Large damaged areas

Selection Table

7

COATING REPAIR

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index

Product description

PERP is designed to repair damaged areas in mill-applied PE coating on steelpipes and ductile cast iron pipes.

The system consists of two components:• PERP filler• PERP repair patch

For repair of damages that do not extend to the steel surface, use PERP MeltStick.

• The PERP Repair System resists high shear forces and shows excellent ad-hesion to commercial polyethylene-based mill-applied coatings

• Specific repair system, and therefore highly economical



PERP XX-YYY x ZZZZZ

PERP and PERP80 are designed to repair the damaged areas on line coatings,mainly two or three-layer.

• PERP repair patch

roll length in mm: 10 M or 30.5 ftroll width in mm: 170 (170 mm or 6.75 inches), 425 (438 mm or 17.25 inches)

PERP type (-, 80)

• PERP repair filler

We recommend three rolls of filler per roll of PERP.Filler materials:• S1137 – 50 x 3 x 3000: mastic filler for PERP and PERP80• S1080 – 50 x 3 x 3000: hotmelt filler for PERP• S1238 – 50 x 3 x 3000: hotmelt filler for PERP80

• Epoxy primer kits (only if bare steel appears)

We recommend three primer kits per roll of tape.• S1239 – Primer-252-kit for PERP• S1301 – Primer-15-kit for PERP 80

• PERP Melt Stick

Size diameter 25 mm x 310 mm (1 inch x 12.2 inches).• PERP-MELT-STICK

Repair system for damaged PE-coatingsPERP

7

COATING REPAIR

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index

1. Clean the damaged areas. Cutaway loose parts of the mill-appliedcoating. Round out nicks and slits.Remove adhering rust and dirt, androughen the mill-applied coating in therepair zone using abrasive paper. Thesurface must be free from oil, greaseand moisture.

2. Cut a length of filler to fit in damagedarea. Pre-heat the damaged zone to+60°C (+140°F), apply the filler, heat itand smooth it down with a hot puttyknife.Important: do not spread the filler overthe mill-applied PE coating.

3. Cut the repair patch for the dam-aged area so that there is an overlap ofat least 50 mm all round. Then heat thepatch on the adhesive side until the ad-hesive softens, shown by the surfaceturning glossy.

4. Using a soft yellow propane flame,warm the PERP repair patch.

5. Smooth down with a gloved handor roller.

Once in place, the PERP repair sys-tem must be smooth and free from airenclosures. Adhesive flow should beevident at all edges of the sleeve.



Repair system for damaged PE-coatingsPERP

7

COATING REPAIR

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index

Overbraid

Fabric jacket

High Performance calcinedcoke breeze ‘backfill’

Conductive polymer anode

8 Cathodic protection

Electrical protection of buried metal structures against corrosion has beenpracticed by owners of pipelines and tanks for over fifty years. The objective isto polarize the soil so that net current flow is toward the protected structurerather than away from it. This practice is commonly referred to as ‘cathodicprotection’ or “CP”.

Cathodically protecting buried metal structures such as pipelines and tanks, andprolonging the life of above-ground storage tank bottoms, are the two primaryapplications for Anodeflex 1500-01 continuous impressed current anode.

6 gauge Copper conductor

Active corrosion protection

AF

LX-1

500

AF

LX-5

00

CATHODIC PROTECTION

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index

An alternative to pipeline recoating

Anodeflex cables have been used successfully by some of the world’s largestpipeline operators since 1985, to extend the effective lives of their pipeline coat-ing systems. Anodeflex provides the pipeline owner with a cost-effective optionto recoating, while staying in compliance with CP regulations. Because it isquicker and far less costly to install Anodeflex than to recoat, more miles ofpipeline may be brought back into compliance using Anodeflex, given a fixedmaintenance or rehabilitation budget.

Anodeflex 1500-01 is a flexible, continuous, carbon-based anode. During manu-facture, conductive polymer is extruded onto a 6-gauge copper conductor. Thepolymer seals the copper conductor from chemical attack, yet allows current toflow from the copper to the environment along the entire length of the anode.The anode cable is centered in a porous woven jacket, which is filled with highperformance coke breeze. The woven jacket is then overbraided with polymericfilament, adding strength and compacting the jacket around the anode.

When energized, the conductive polymer anode provides current to the cokebreeze. Electrochemical reactions occur within the coke breeze, sustainingcurrent flow to the target structure.

Anodeflex 1500-01

Anodeflex 500 is a flexible, continuous, carbon-based anode. During manufac-ture, conductive polymer is extruded onto a 6-gauge copper conductor. Thepolymer seals the copper conductor from chemical attack, yet allows current toflow from the copper to the environment along the entire length of the anode.

The anode cable is laid (inserted) into a prepared bed of coke breeze.

When energized, the conductive polymer anode provides current to the cokebreeze. Electrochemical reactions occur within the coke breeze, sustainingcurrent flow to the target structure.

Anodeflex 500

CATHODIC PROTECTION

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index

Discreteanode

deep well

Discreteanode

Discreteanode

Discreteanode

Potential pipe to soil(neg. volts)

Ideal range- 0.85 to -1.2 Volts

Pipeline length

Anodeflex

Discrete Anode

Deep Well

The correct amount of current and no more

Comparison of Anodeflex to discrete anodes ‘off potential’

Conventional groundbeds have performed very well on pipelines with effectivecoatings. However, as coatings deteriorate the effective protection distance ofthese discrete anodes rapidly decrease, and on poorly coated pipelines theeffective protection distance can be as wide as 100 m (328 feet).Most current under such circumstances is directed to the part of the pipe near-est the groundbed – resulting in over-protection and subsequent acceleratedlocalised coating disbondment, whilst under-protection exists just a few metresfurther along the pipeline.

Anodeflex being a continuous anode, all the way along the pipeline, is able tosupply current exactly where it's needed – no more and no less. It is thereforean ideal coating rehabilitation method which can be installed at a fraction of thecost of recoating, and allows for the pipeline to remain in full operation.

8

Ease of installation

Also for tank bottoms

Anodeflex 1500-01 is a complete anode. Delivered on reels of approximately500 m (1640 feet), Anodeflex 1500-01 can be plowed in or simply laid in anexisting ditch. Because the anode is pre-packaged with its own calcined cokebreeze backfill, it is also ideal for installation by directional drilling. This featureis particularly attractive in congested, urban areas – as well as when the anodemust be installed under a river bed, or in an environmentally sensitive area.

Whether installed beneath a new ASTduring construction, or placed in theinterstitial layer between old and newbottoms, Anodeflex 1500-01 providesevenly distributed CP current withoutoverprotecting. For existing AST's,Anodeflex can be installed via direc-tional drilling underneath the tank – orfor smaller tanks, may be plowed inaround the tank perimeter.

Rectifier

Anodeflex

Typical Anodeflex 1500-01 Tank Design

CATHODIC PROTECTION

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index

8

To help designing the system a special computer program is available whichcalculates the cathodic protection circuit lengths, anode to pipe distances, sup-ply voltages and current demands for each individual Anodeflex section.

The Anodeflex system is a unique method of distributing cathodic protectioncurrent. It can be the most cos-effective way to protect buried pipelines withdeteriorated coatings. Run alongside the pipes, it provides uniform protectioncurrent to every point on pipelines where clos interval surveys have shown thatexisting ground beds do not provide adequate protection.

Key to the products performance is the conductive polymer coated copper con-ductor. This unique construction allows current to flow long distances down theanode cable whilst a small amount of cathodic protection current continuouslytrickles through the conductive coating all along its length.

Because Anodeflex can be installed at close proximity to the structure it pro-tects, the Anodeflex minimizes stray current to other structures further away.

The anode’s close proximity to the structure and large effective surface areamean lower overall resistance, an important factor in high resistivity environ-ments.

Application

Design

The long-line anode is delivered on spools. The cable anode is available inlengths sufficient for most applications. Pipes are protected by arranging severallengths of the anode in simple circuit designs.

Delivery

It is imperative to install Anodeflex 500 centrally in a 4 inch coke breeze column.The coke breeze Tyco Adhesives recommends is calcinated petroleum cokebreeze according to the specification that follows.

Since the lifetime of the system depends upon the coke breeze surrounding thepolymeric cable, care should be taken to assure the correct amount of cokebreeze is installed all along the circuit length.Also this installation method should only be used in those soils which will main-tain the coke breeze around the polymeric cable during its entire lifetime.For those applications where the coke breeze can be washed away Tyco Adhe-sives does recommend its Raychem long-line anode with prepackaged cokebreeze.

Coke breeze requirements• calcined petroleum coke (fluid or delayed)• predominately spherical or round• bulk density > 65 lb/ft3 = 961 kg/m3

• fixed carbin > 99%• resistivity (10 Bar) ≤ 0.1 Ωcm• ash ≤ 0.5%• no volatile at 950°C• size as small as possible, but must necessarily meet:

1% between 1.2 mm (Mesh 16) and 12.7 mm (1/2 inch) 99% < 1.2 mm

Installation

Recommended maximum design current output = 16 mA/ft Anode lenght(52 mA/m) if installed in a 4" coke breeze column.

Product properties

Long-Line flexible Anode for Impressed Current CathodicProtection ANODEFLEX 500

CATHODIC PROTECTION

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index

8Anodeflex Raychem Nominal WeightDescription Part number diameterAnodeflex AFLX-500 0.5 inch (13 mm) 260 g/m (0,175 lb/ft)

Components Raychem UnitDescription Part numberAnodeflex Tee Splice Kit AFLX-500-TEE each

Anodeflex In-line Splice Kit AFLX-500-SPLICE each

Anodeflex End Seal Kit AFLX-500-CAP each

Ordering Information

Note– Similar component versions also exist including a screw connector and

cleaning tissue. Add -C to the part number.– For more information on the properties and test methods, consult Raychem

Technical Specification RUD 6077 or contact your local sales engineer.

Long-Line flexible Anode for Impressed Current CathodicProtection ANODEFLEX 500

CATHODIC PROTECTION

R

index

8

On poorly coated pipelines, where effective polarization can no longer beachieved, Anodeflex 1500-1 can often be installed instead of expensiverecoating. Both on songle and multi-parallel pipelines, safe levels of polarizationwill be restored at every point. The system avoids difficult field recoating andgreatly reduces environmental disturbance.

Also above ground storage tank bottoms and buried tanks can more effectivelybe protected from corrosion using this continuously distributed, close proximityanode system. The protective current

Anodeflex 1500-1 is a long-line, flexible, cable-like anode which is placed incontinuous close proximity to the target structure. Hence uniform distribution ofcathodic protection current is achieved on many applications where conven-tional anode ground beds do not work.

Key to the product’s performance is the central conductive polymer coated cop-per conductor. This unique construction allows current to flow long distancesdown the center conductor while allowing a small cathodic protection current tocontinuously pass through the conductive polymer all along the length of theanode.

The central anode cable is surrounded by a factory prepackaged high conduc-tivity coke breeze, held in place by a porous woven acid resistant jacket. Thisarragement avoids handling loose coke breeze and simplifies field installation.

The improved current distribution increases anode efficiency, helps prevent overvoltage problems such as hydrogen generation and associated rapid coatingdisbondment. In addition, interference to foreign structures is minimized.

Product features

Applications

The long-line anode is delivered on spools. Anodeflex is available in lengthssufficient for most applications. Pipes are protected by arranging several lengthsof the anode in simple circuit designs.

Delivery

To help design the cathodic protection system, special computer programs areavailable which calculate the Anodeflex circuit lengths, anode to pipe distances,supply voltages and current demands for pipeline and tank applications.

Design

The anode is installed as a standard low voltage cable. No additioned cokebreeze has to be installed around the anode.

Installation

• Recommended Maximum Design 16mA/ft Anode lenght (52 mA/m)Current Output in Soil

• Minimum Installation and Storage 0°F (–18°C)Temperature

• Minimum Bend Radius 20 inch (500 mm)

Product properties

Long-Line flexible Anode for Impressed Current CathodicProtection ANODEFLEX 1500-01

CATHODIC PROTECTION

R

index

8Anodeflex Raychem Nominal WeightDescription Part number diameterAnodeflex AFLX-1500-01 1.5 inch (38 mm) 1 lb/ft (1,49 kg/m)

Components Raychem UnitDescription Part numberAnodeflex Tee Splice Kit AFLX-1500-01-TEE each

Anodeflex In-line Splice Kit AFLX-1500-01-SPLICE each

Anodeflex End Seal Kit AFLX-1500-01-CAP each

Ordering Information

Note– Similar component versions also exist including a screw connector and

cleaning tissue. Add -C to the part number.– For more information on the properties and test methods, consult Raychem

Technical Specification RUD 6077 or contact your local sales engineer.

Long-Line flexible Anode for Impressed Current CathodicProtection ANODEFLEX 1500-01

Like any cathodic protection system, the Raychem Anodeflex system must be optimized for particular design conditions.Severe environments may limit the lifetime. Anodeflex is a flexible carbon cable anode system. When all the active anodematerial available around the polymeric cable is consumed, the anode will no longer function. Tyco Adhesives warrants thatAnodeflex meets the internal Tyco Adhesives specification, but the purchaser must rely on its own engineering experiencejudgment and skill to ascertain whether or not Anodeflex is fit for the particular purpose proposed by the purchaser.All of the above information, including illustrations, is believed to be reliable. Users however, should independently evaluatethe suitability of each product fot their application. Tyco Adhesives makes no warranties as to the accuracy or completenessof the information and disclaims any liability regarding its use. Tyco Adhesives’s only obligations are those in het StandardTerms and Conditions of Sales for this product and in no case will Tyco Adhesives be liable for any incidental, indirect orconsequential damages arising from the sale, resale, use or misuse of the product. Tyco Adhesives specifications are subjectto change without notice. In addition Tyco Adhesives reserves the right to make changes in materials or processing, withoutnotification to the Buyer, which do not affect compliance with any applicable specification.

Raychem and Anodeflex are trademarks of Tyco

CATHODIC PROTECTION

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index

Liquid epoxy coatings for transmission pipelines, girth welds,bend and fittings R80-R95

9 Liquid coatings

R80-R95 Liquid epoxy coatings

Tyco Adhesives introduces new high performance liquid epoxy coatings de-signed for the corrosion protection of buried pipelines, operating at tempera-tures up to 95°C (203°F). Epoxy coatings can be used for new construction,including girthwelds, bends, fittings etc., and for the recoating of existing livelines. The coatings are is available in both brush and spray applied grades.

R80/R95 Liquid epoxy coating

R80/R95 offers excellent performance in the following applications:• Corrosion protection of girth welds on new precoated pipelines• On-site and plant-applied line coating on new pipelines• Rehabilitation of existing pipelines• Corrosion protection of valves, flanges, bends, and components

Under normal weather conditions the liquid coating requires no steel preheatand eliminates the need for induction or catalytic heaters. R80/R95 coating isideal for retrofit corrosion protection of flowing lines where preheating is imprac-tical. Since R80/R95 can be applied to horizontal and vertical surfaces of anyshape, it is also ideal for the corrosion protection of valves, fittings, and othercomplex geometric shapes.

Applications

• Easy application by brush or spray• Excellent performance• Solvent free• Fast cure

R80/R95 is a high-performance liquid epoxy coating for the corrosion protectionof pipeline systems. Based on laboratory tests, including cathodic disbondment,it is suitable for pipes operating at temperatures up to 95°C (203°F)A copolymerized, 100% solids, isocyanate-free coating, R80/R95 combines theadhesion, toughness, and anticorrosion properties of epoxy with the ease ofapplication of a liquid coating.

R80/R95 coating can be applied by airless spray or by roller, pad, or brush onsteel surfaces above 10°C (50°F). After the surface is blast-cleaned, the R80/R95 components are mixed and applied to a minimum thickness of 0.5 mm(0.02 inches). The coating is tack free in 1.5 hours and cures hard in 4 hours at25°C (77°F). Applicators must be certified. Training, application specifications inEnglish and Spanish, and material safety data sheets (MSDSs) are available.

Installation

R80/R95 epoxy exhibits superior performance in such important tests as ca-thodic disbondment at elevaled temperatures; adhesion to steel; salt spray; andresistance to impact, chemicals, and hot water. It also meets a variety of inter-national standards for physical, chemical, and electrical properties.

Performance

LIQUID COATINGS

R

index

R95 provides excellent performance on a variety of line coatings. For applica-tions on particular substrates, contact Raychem.

Compatibility

Handling

Shipping, storing, and handling 15°C–40°C (59°F–104°F)temperature

Shelf life 2 yearsMixing ratio by volume 3:1 (base:hardener)

Workable pot life after mixing 7–15 min at 25°C (77°F)

Tack-free cure time 1.5 h at 25°C (77°F)

Hard cure time 4 h at 25°C (77°F)Application surface temperature range 10°C to 100°C (50°F–212°F)

Application humidity Below 90%, surface at least 3°C(37.4°F) above dew point

ApplicationApplication methods Brush, pad, roller, and airless spray

Coverage (practical) 1–1.5 m2/l (10.76–16.15 sqft/ltr)

Wet/dry film thickness 0.7 mm (0.028 inches)(0.5 mm (0.02 inches) minimum)

Single-application maximum dry film 1.25 mm (0.05 inches)thickness on a vertical surface

Surface preparation Grit-blasted to SA 2 1/2

Surface roughness profile 62.5–100 microns (2.5–4 mils)

Recoat interval 2 hours at 25°C (77°F). After 2 hours,surface must be roughened to a mini-mum surface profile of 50 microns.

Tool cleaner before cure Methyl ethyl ketone (MEK) or xylene

Tool cleaner after cure Paint stripper or immersion in MEK for12 hours

Additional properties

R80/R95 epoxy is supplied in kits containing base and hardener in the proper3:1 ratio by volume. The 1.6-liter brush-grade kit is premeasured and supplied inoversized pails to enable the installer to pour the hardener directly into the basefor mixing with a mechanical stirrer. Application accessories, such as stirrers,pads, and rollers, are also available and may be ordered separately.


Contents Weight Order

Description Volume (l) Base Hardener (kg) quantity

R80-Epoxy-Spray-800L 800 Three 200-liter drums One 200-liter drum 1175 1R80-Epoxy-Brush-60L 60 Three 15-liter pails One 15-liter pail 90 1

R80-Epoxy-Brush-1.6L 1.6 One 1.2-liter pail One 0.4-liter can 2.4 Multiples of 4

R95-Epoxy-Spray-800L 800 Three 200-liter drums One 200-liter drum 1175 1R95-Epoxy-Brush-60L 60 Three 15-liter pails One 15-liter pail 90 1

R95-Epoxy-Brush-1.6L 1.6 One 1.2-liter pail One 0.4-liter can 2.4 Multiples of 4

LIQUID COATINGS

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index

Accessories10

EQ-TO-NOZZLE-BN80

EQ-TO-NOZZLE-BN60

EQ-TO-NOZZLE-BN40

EQ-TO-NOZZLE-BN25

EQ-TO-HANDLE-PILOT-3488

EQ-TO-HANDLE-3486

EQ-TO-HOSE-4M-701291

EQ-TO-HAN-701291

EQ-TO-REGU-US-3084-01

EQ-TO-REGU-IT-3084-04

EQ-TO-REGU-EU-3084-05

M20 X1

R 3/8 RH

M14X1

M14X1R 3/8 LH

POL 0.88 inches-14GO-LH

W 20.0-14LH

W 21.8-14LH


EQ-FH-2601A-KIT: Complete torch kit

Torches

ACCESSOIRES

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• roller:EQ-ROLLER-FLAT-SILICON

Installation equipment

• temperature stick:RM-TEMP-IN-STICK-60°C/70°C (140°F/158°F)

• temperature pyrometer:RM-PYROMETER+ surface contact probe:RM-ROLLER-PROBE-SENSOR

• plastic scraper for bevel-ling mill coating:EQ-PE-SCRAPER+ replacement blade:EQ-PE-BLADE


Miscellaneous

• heatshield for line coating:EQ-HEATSHIELD-150x3x25M

• field peel test set:EQ-PEELTEST-SET

• working gloves:EQ-GLOVES-PAIR


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ACCESSOIRES

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Primer equipment

10Epoxy primer S1239 and S1301Primer is available in bulk packages and in small kits


• Small Epoxy primer kits:S1239-PRIMER-KIT-252S1301-PRIMER-15-KIT

Kits include appropriate quantities ofresin (part A) and hardener (part B),a stirring stick (EQ-PR-MIXING-STICK), primer safety gloves(EQ-PR-GLOVES) and an applicatorpad (EQ-PR-APPLICATOR-3).Kits contain sufficient primer for up to1 square meter (11 square feet) ofsurface coverage.

• Bulk Epoxy primer:S1239: S1239-PART-A-14.7L-OV

S1239-PART-B-17L-OVS1301: S1301-PART-A-17L-OV

S1301-PART-B-17L-OV

Bulk epoxy primer consist of 2-con-tainers of resin Part A and 1-containerof hardener part B.1 ltr* of mixed bulk primer covers aminimum of 6.7 m2 (72 square feet)surface.When using bulk epoxy primer, it isnecessary to order primer pumpsetsand applicator pads seperately.Applicator pad kits are available andthese contain 100 pads, 100 mixingcups and 100 gloves:RM-BULK-ACCESSORIES-KIT.

*1 ltr = 0.91 quart

ACCESSOIRES

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• primer applicator pad:EQ-PR-APPLICATOR-3

• primer mixing stick:EQ-PR-MIXING STICK

• primer mixing cup:EQ-PR-CUP-460

• primer safety gloves:EQ-PR-GLOVES

• kit:100 applicators, sticks, cups andgloves :RM-BULK-ACCESSORIES-KIT

• primer pumpset S1301 primer:1pc EQ-PR-S1301-PUMP2-A1pc EQ-PR-S1301-PUMP2-B

or

• primer pumpset S1239 primer:EQ-PR-S1239-PUMP2-AEQ-PR-S1239-PUMP2-A

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New technologies

The use of fiberglass- reinforced materials enables installa-tion to be achieved under extreme conditions, e.g. in hori-zontal drillings or offshore service.

The special structure gives this kind of coating great resist-ance to mechanical stresses, while the penetration resist-ance is several times higher than that of unreinforced car-rier materials.

Dirax joint protection for directional drilling

11

RayJoint

RayJoint is Tyco Adhesives's new jointing system for pre-insulated pipes. It consists of a crosslinked heat-shrinkablepolyethylene casing installed with sealing strips – for a wa-tertight bond.

RayJoint can be easily installed using standard gas poweredblow torches. The crosslinked nature of the polyethylenecasing means it can withstand the heat needed to shrink thecasing and bond the underlying sealant strip without itselfsuffering damage. Consequently, no additional outsideendseals are required.

Thanks to their excellent thermal stability, RayJoint casingscan be stored and transported without risk of pre-shrinkingeven in high temperatures.

The polyethylene casing provides outstanding protectionagainst the environment – resisting attack from chemicals,water, and heat as well as abrasion and chemical stress.

R80 and 95-Liquid epoxy coating

Tyco Adhesives introduces new high performance liquidepoxy coatings designed for the corrosion protection ofburied pipelines, operating at temperatures up to 95°C(203°F). Epoxy coatings can be used for new construction,including girthwelds, bends, fittings etc., and for therecoating of existing live lines. The coatings are is availablein both brush and spray applied grades.

NEW TECHNOLOGIES

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General Technical data12

Steel pipe sizes

DN outside pipe diameterinches mm inch

80 3 88,9 3.500100 4 114,3 4.500

125 5 141,3 5.563

150 6 168,3 6.625

200 8 219,1 8.625250 10 273,1 10.750

300 12 323,9 12.750

350 14 355,6 14.000400 16 406,4 16.000

450 18 457,2 18.000

500 20 508,0 20.000600 24 609,6 24.000

700 28 711,2 28.000

800 32 812,8 32.000

900 36 914,4 36.0001000 40 1016,0 40.000

1100 44 1120,0 44.000

1200 48 1220,0 48.0001400 56 1422,0 56.000

1600 64 1620,0 64.000

Conversion table

Length inch foot yard stat. naut. cm m kmmile mile

1 mil 0.001 - - - - 2.54.103 - -1 inch 1 0.0833 0.0278 - - 2.540 0.0254 -

1 foot 12 1 0.3333 - - 30.48 0.3048 -

1 yard 36 3 1 - - 91.44 0.9144 -

1 stat. mile 63360 5280 1760 1 0.8678 - 1609 1.6091 naut. mile 72950 6080 2026 1.152 1 - 1853 1.853

1 cm 0.3937 0.0328 - - - 1 0,01 -

1 m 39.37 3.281 1.094 - - 100 1 0,0011 km 39370 3.281 1093.6 0.6214 0.5396 - 1000 1

Surface square square square square acre cm2 m2 a ha km2

inch foot yard mile

1 circular mil - - - - - 5.067.106 - - - -

1 square inch 1 - - - - 6.452 - - - -1 square foot 144 1 0.1111 - - 929 0.0929 - - -

1 square yard 1296 9 1 - - 8361 0.8361 - - -

1 square mile - - - 1 640 - - - 259 2.591 acre - 43560 4840 0.0016 1 - 4047 40.5 0.405 -

1 cm2 0.155 - - - - 1 0,0001 - - -

1m2 1550 10.76 1.196 - - 10000 1 0,01 - -1a - 1076 119.6 - 0.0247 - 100 1 0,01 -

1ha - - - 0.0039 2.47 - 10000 100 1 0,01

1km2 - - - 0.3861 247.1 - - 10000 100 1

Volume cubic cubic cubic US Imp. US Imp Imp cm3 dm3

inch foot yard fl. oz fl. oz gallon gallon pint (L)

1 cubic inch 1 - - 0.5541 0.5768 - - 0.0288 16.39 0.0164

1 cubic foot 1728 1 0.0370 957.5 996.6 7.481 6.232 49.83 - 28.32

1 cubic yard 46656 27 1 25853 26909 202 168.2 1345 - 764.61 US fl. oz 1.805 - - 1 1.041 - - 0.0520 29.57 0.0296

1 Imp. fl. oz 1.734 - - 0.9607 1 - - 0.05 28.41 0.0284

1 US gallon 231 0.1337 - 128 133.2 1 0.8327 6.662 3785 3.7851 Imp. gallon 277.4 0.1603 - 153.7 160 1.201 1 8 4546 4.546

1 Imp. pint 34.68 0,02 - 19.21 20 0.1501 0.125 1 568.2 0.5682

1 cm3 0.061 - - 0.0338 0.0353 - - - 1 0,0011 dm3 61.02 0.035 0.0013 33.81 35.3 0.2642 0.22 1.76 1000 1

Weight oz lb stone US Imp. US Brit g kg tcwt cwt ton ton

1 oz 1 0.0625 0.004 - - - - 28.35 0.028 -

1 lb 16 1 0.071 0.01 0.009 - - 453.6 0.454 -1 stone 224 14 1 0.14 0.125 0.007 0.0663 6350 6.35 0.0064

1 US cwt 1600 100 7.143 1 0.8929 0.05 0.0446 45359 45.36 0.0454

1 Imp. cwt 1792 112 8 1.12 1 0.056 0.05 50802 50.8 0.05081 US ton 32000 2000 142.9 20 17.841 1 0.3929 907190 907.2 0.907

1 Brit ton 35840 2240 160 22.40 20 1.120 1 1016050 1016 1.016

1 g 0,0353 - - - - - - 1 0,001 -

1 kg 35.27 2.205 0.157 0.022 0.020 0.0011 0.00098 1000 1 0,0011 t 35274 2204.6 157.47 22.05 19.685 1.1023 0.3642 - 1000 1

GENERAL TECHNICAL DATA

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Corrosion Protection Group

Europe: Fax (32) 16 55 36 74 US: Fax 1 781 440 6271Customer service center

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telephone: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fax: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

e-mail: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sender

Please send

n Technical information

for the following products

n TPS n TPSM-C30 n WPCT n WPC B30

n WPC C30 n WPCZ n WPC B50 n WPC C50

n WPC100M n WPC120 n HTLP60 n WPC65M

n DIRAX n FLEXCLAD n CSEM-F / CASEAL (US) n HTLP80

n PERP n AFLX-1500-01 n AFLX-500 n FCWS-F/ FLANGESEAL (US)

n RAYJOINT n LIQUID EPOXY COATING

n Information on products for gas & water distribution pipelines

n Information on district heating products

Other information requirement

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In the US:1400 Providence HwyNorwood, MA 02062 USAInt’l Tel: +1 781 440-6161US Toll Free: +1 800 248-0149Fax: +1 781 440-6271E-mail: [email protected]

Anodeflex, CASEAL, DIRAX, RAYCLAD, RayJoint, R95, WPC and WPCT are trademarks of Tyco Adhesives.

All of the above information, including illustrations, is believed to be reliable. Users however, should independently evaluate the suitabilityof each product for their application. Tyco Adhesives makes no warranties as to the accuracy or completeness of the information and disclaimsany liability regarding its use. Tyco Adhesives’s only obligations are those in the Standard Terms and Conditions of Sale for this product andin no case will Tyco Adhesives be liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuseof the product. Tyco Adhesives Specifications are subject to change without notice. In addition Tyco Adhesives reserves the right to makechanges in materials or processing, without notification to the Buyer, which do not affect compliance with any applicable specification.

In Europe:Tyco Adhesives EuropeNieuwlandlaan B15B-3200 Aarschot, BelgiumTel: 32 16 55 36 00Fax: 32 16 55 36 74E-mail: [email protected]

Napa-Server

New Stamp

Documents

Corrosion protection of pipelines - Napa Teknapatek.co.th/pdf/pipeline_products_catalogue.pdf · 285 mm (11.25 inches), 450 mm (17.75 inches), 600 mm (23.50 inches) and 870 mm (34.25