A protective PVC tape incorrectly installed had trapped water and condensation against a three metre section of 100mm steel pipe carrying natural gas in an industrial site CHP system, leaving a heavily corroded area which required refurbishment before it became breached.

Case Study Overview

Site Industrial plant
Location Puerto Rico
Pipe Type 100mm steel natural gas pipe
Repair Type Pipe reinforcement
Products Liquid Metal Epoxy Coating, SylWrap Pipe Repair Bandage

Pipe Defect

The steel pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It hung on a series of U-shaped supports welded to I-beams suspended from the ceiling of the building.

When installed, the pipe had been wrapped with a protective PVC tape. Incorrect application of this tape had left a three metre section where it was possible for water and condensation to become trapped against the steel line.

This had caused heavy corrosion to develop, which was particularly prevalent at the bottom of the pipe and around the area where the section in question rested on its U-shaped support.

SylWrap Solution

The plant decided to use the Sylmasta Pipe Refurbishment System to bring the weakened section of the line back up to specification, by reinforcing and strengthening the metalwork and giving the pipe greater protection from corrosion.

First, the U-shaped support was cut away from the I-beam to better access the line. The PVC tape was removed and the pipe thoroughly cleaned. Rust, grime and paint were ground off, followed by the use of alcoholic cloths to remove any remaining residue.

Liquid Metal Epoxy Coating was brush applied across the three metre section to repair the damage caused by corrosion and restore the exterior of the pipe. It set to form a smooth, hard wearing, outer metallic surface to act as a shield against corrosion and chemical attack.

Whilst the Liquid Metal coating remained tacky, a SylWrap Pipe Repair Bandage was wrapped around the area of the line which had contact with the U-shaped support. Within minutes, SylWrap cured to form a rock-hard, impact resistant shell around the pipe.

This further increased the thickness of the weakened section and provided an additional layer of protection. A second coating of Liquid Metal was then painted over the hardened SylWrap Bandage to improve the appearance of the line.

Once the refurbishment of the pipe had been completed, the U-shaped support was welded back to the I-beam. The line was fixed to the U-support via a pipe support clamp to reduce vibrations and the clamp coated in Liquid Metal.

Outcome

Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented a potentially expensive and disruptive future repair or replacement of the three metre section being needed when corrosion eventually ate through the line.

Follow Up

The plant were very happy with the outcome and how easy their maintenance team had found the repair. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and other sites they operate across North America.

Products Used

Liquid Metal
Epoxy coating brush applied to form a new metallic surface over the damaged pipe

SylWrap Pipe Repair Bandage
Water-activated wrap which reinforces pipes by increasing thickness of weakened sections

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