Tag: Industrial Metal

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Case Study: SylWrap Pipe Repair Passes ASME PCC-2 401-III Qualification Standard

Industrial Metal and SylWrap HD Bandage pass PCC-2 401-III qualification testing in a repair on a high temperature steel pipe

Composite pipe repair using Sylmasta products exceeds 309.6 bar pressure resistance to qualify for ASME PCC-2 401-III

SylWrap HD Pipe Repair Bandage and Industrial Metal Epoxy Paste make a repair independently witnessed and verified as passing ASME PCC-2 Appendix 401-III – Short Term Spool Survival standard by exceeding 309.6 bar pressure resistance.

Case Study Data

Site
Test site
Location
United Kingdom
Repair Type
Composite pipe repair pressure test
Defect
Carbon steel pipe machined back to 1mm outer wall thickness

Products Used

Industrial Metal Epoxy Paste
Metal filled epoxy paste used to strengthen pipelines by rebuilding weakened outer walls back towards original thickness

SylWrap HD Pipe Repair Bandage
Composite repair wrap with water activated resin sets rock hard to reinforce pipework with a thickened, impact resistant sleeve

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Case Study Details

ASME PCC-2 Appendix 401-III – Short Term Spool Survival is a test which assesses the ability of a composite pipe repair system to restore the integrity of a weakened pipeline back to the strength of the original pipe.

Industries like oil and gas, chemical processing and power generation where high pressure systems and hazardous pipe content are present require pipe repairs to be ASME PCC-2 401-III compliant.

To qualify Sylmasta HD Pipe Repair Bandage and Industrial Metal for ASME PCC-2 401-III standard repairs, Sylmasta carried out a test independently witnessed and verified by a UKAS registered company.

A steel pipe spool similar to the type of pipe found in high temperature applications was fabricated for the test

The test was performed on an ASTM A106 Grade B pipe spool. This type of carbon steel pipe is often used in high temperature environments such as steam and gas lines.

A defect was machined into the spool to reduce wall thickness down to 1mm, accounting for an 86 percent weakening of the pipe.

An defect was machined into the pipe, reducing wall thickness down to 1mm

Based on the measured yield strength of the pipe, diameter and original wall thickness, the repair needed to withstand 309.6 bar of pressure to pass the test and certify the materials as PCC-2 401-III compliant.

Before the repair, a flap wheel was used to clean the area back to bare metal. The whole area was then thoroughly cleaned using a solvent degreaser to remove any remaining traces of foreign substances.

Industrial Metal Epoxy Paste was used to fill in the defect. It rebuilt the pipe wall back towards original thickness, and acted as a load transfer medium between the pipe spool and SylWrap HD.

Industrial Metal is applied to a pipe during successful testing to make an ASME PCC-2 401-III standard repair
Industrial Metal filled the defect in the pipe, rebuilding the degraded pipe wall back towards original thickness

The two parts were mixed together until turning a uniform grey colour. Industrial Metal was then applied using a putty knife, ensuring maximum contact between the spool and the epoxy paste.

Industrial Metal was allowed to fully set before the flap wheel was used to smooth the cured material and the area around surrounding it, followed by further cleaning with degreaser.

Industrial Metal Epoxy Paste used to successfully repair a pipe to ASME PCC-2 401-III standard
Once Industrial Metal had fully set, the cured material and area surrounding it were smoothed off and cleaned

The Sylmasta Pipe Refurbishment Calculator helped determine the size and number of SylWrap HD Pipe Repair Bandage needed to reinforce the repair so it became strong enough to hold 309.6 bar pressure.

SylWrap HD Pipe Repair Bandage used to successfully repair a pipe to ASME PCC-2 401-III standard
Five SYL633HD Bandages were used over the defect

Five SYL633HD Bandages were used for the repair. The fast working, water activated resin began to cure within minutes to form a rock-hard, impact resistant shell.

Once SylWrap HD had set, the pipe spool was pressure tested by a UK-based specialist using calibrated and certified pressure gauges. The results were recorded using a data logger.

SylWrap HD undergoing pressure testing to qualify for PCC-2 pipe repair
The pipe spool was pressure tested using calibrated and certified pressure gauges with results recorded on a data logger

The repair exceeded the 309.6 bar required to pass PCC-2 401-III, eventually failing when pressure reached 310.29 bar and water began leaking through the edges.

The repair exceeded the 309.6 bar required to meet PCC-2 401-III, failing when pressure reached 310.29 bar

With the test signed off as a success, composite pipe repairs using SylWrap HD and Industrial Metal are qualified to meet ASME PCC-2 401-III standard.

To determine the quantity of Sylmasta materials needed to make a composite pipe repair conforming to PCC-2 401-III standard, please use the ASME PCC-2 Compliant Repair Calculator below.

The calculator serves only as a guide. Judgement should be made on the exact repair based upon all conditions. Please contact Sylmasta for more information or if you need help with a specific application.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Corroded 30-Metre Section of Sewer Force Main In Underground Vault Repair

A severely corroded sewer force main pipe in Hawaii undergoes repair and refurbishment using the Sylmasta Pipe Refurbishment System

Say aloha to a sewer force main in Hawaii restored from a corroded state by a repair made using the Sylmasta Pipe Refurbishment System

An engineering company in Hawaii refurbish a severely corroded 30-metre section of 450mm ductile iron sewer force main inside an underground vault, rectifying a previous repair attempt which ended up sandblasting a 75mm round hole in the pipe.

Case Study Data

Site
Sewer force main
Location
Hawaii
Repair Type
Pipe repair and refurbishment
Defect
Severely corroded 450mm ductile iron pipe, including 75mm round hole

Products Used

Industrial Metal Epoxy Paste
Metal-filled epoxy paste used to bridge large holes, rebuild weakened pipes and restore surface profile

Liquid Metal Epoxy Coating
Brush applied coating which cures to a hard wearing, metallic surface for protecting pipes against corrosion

SylWrap Pipe Repair Bandage
Composite repair wrap with water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

Case Study PDF

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Case Study Details

The 450mm ductile iron pipe inside the vault was the final section of the sewer force main before it discharged into a manhole housing a gravity collection system. Its operating pressure was around 3 bar.

It was installed in the 1970s. Conditions inside the often-flooded vault over a period of nearly 50 years had led to severe exterior corrosion and a significantly weakened pipe.

Water was pumped out of the flooded vault before repair

A recent attempt to add structural strength and protect against further corrosion involved sandblasting the line prior to coating with epoxy. Unfortunately, the contractor failed to realise just how weakened the ductile iron had become.

Sandblasting to clean the pipe subsequently put a 75mm round hole in the top of the sewer between a flange and the concrete wall where the main entered the adjacent manhole. Wastewater could escape through this hole when the line was pressurised.

To seal the leak in the pipe, the contractors ordered a pipe repair clamp specifically fabricated for the line. But because the surface was so badly deformed by corrosion, it was impossible for the clamp to achieve a watertight seal. There were also concerns that tightening the clamp fully would further breach the brittle metalwork.

The pipe surface was severely corroded, leaving it weakened and brittle

The contractors contacted Sylmasta for assistance with the corroded sewer main repair. They needed to improve the surface profile of the pipe to make the clamp effective, before refurbishing the entire 30-metre section inside the vault to keep the line operational and protect against further degrading.

Any repair method had to take into account the weakness of the line and the damage already done by sandblasting. Sylmasta therefore recommended using Stages 2, 3 and 4 of their Pipe Refurbishment System.

The hole was attended to first. Wire mesh was used to bridge the gap. Industrial Metal Epoxy Paste was then applied around the entire diameter of the pipe between the flange and the wall, including over the hole. The wire mesh prevented any epoxy paste entering the pipe.

Sandblasting to clean the pipe during a previous repair attempt left a hole in the pipe, through which water could escape when the sewer main was pressurised

Industrial Metal is a two-part epoxy paste used to rebuild weakened metalwork and improve surface condition of pipes. In this application, 5kg of Industrial Metal filled in all imperfections caused by pitting and increased pipe thickness surrounding the hole.

Once cured, Industrial Metal sealed the hole and rebuilt the pipe, leaving it strong enough to withstand the clamp being fitted and smooth enough to ensure a watertight seal could now be achieved.

Industrial Metal Epoxy Paste used to repair a hole in a corroded sewer main line
Industrial Metal was applied to seal the hole and rebuild the area of pipe around it, enabling a repair clamp to be fitted

Industrial Metal could have held the leak of its own accord. The contractors though decided to take a belt and braces approach by also fitting the clamp, seeing as it had been specifically made for this sewer line.

Attention next turned to refurbishing the rest of the corroded sewer main. Loose material was carefully cleaned off using wire brushes before the sewer main was painted with Liquid Metal Epoxy Coating.

10kg of Liquid Metal was used to apply two coatings across the entire 30-metre pipe, the two flanges at either end and the coupling in the middle. Re-coat time was four hours, meaning the application of Liquid Metal took one day.

Corroded sewer main pipe in Hawaii before undergoing repair and refurbishment with Liquid Metal
Liquid Metal used to repair a heavily corroded sewer main ductile iron pipe
Liquid Metal refurbished the sewer main by creating a metallic external shield around the entire pipe

Liquid Metal cured to create a new, metallic, hard-wearing pipe exterior for the sewer main, providing a shield against corrosion and a waterproof barrier against future leaks.

The final stage of the repair saw the sewer main given further reinforcement using 20 x SYL866HD SylWrap Pipe Repair Bandage. SylWrap Bandage is a composite repair wrap with a water-activated resin.

It was wrapped and smoothed around the whole pipe, curing within minutes to form a rock-hard, impact resistant layer of further protection. Six layers of SylWrap Bandage were used based on the 3 bar operating pressure of the sewer main.

Application of SylWrap Pipe Repair Bandage to a heavily corroded sewer main pipe in Hawaii
SylWrap Pipe Repair Bandage forms a rock hard, impact resistant layer of protection for a sewer main ductile iron pipe in Hawaii
The repair was completed by wrapping the entire 30-metre pipe with SylWrap Bandage for a rock-hard, reinforced final layer of protection

From sealing the hole to reinforcement with SylWrap Bandage, the repair was completed over the course of one week. The contractors were impressed with how easy all three Sylmasta products were to apply given the cramped, wet and dirty conditions inside the vault.

They had originally planned to encase the sewer main in concrete after refurbishment as an additional means of protection. This was no longer deemed necessary once they saw the strength and effectiveness of the repair.

At a total cost of just under $5000 including delivery to Hawaii, refurbishing the corroded sewer force main provided a significant financial saving compared to ripping out the pipe and replacing it.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Dairy Delivery Truck 466 International Engine Cracked Timing Cover Repair

The repair of a crack in a 466 International engine timing cover made using Industrial Metal Epoxy Paste

The delivery truck timing cover repair which meant no crying over spilt milk for a dairy in Puerto Rico

Replacing a delivery truck’s 466 International engine timing cover after it developed a hairline crack was set to cost a milk company in Puerto Rico $1000 until Sylmasta formulated a faster, more cost-effective repair method.

Case Study Data

Repair Type
Timing cover repair
Defect
Crack in 466 International engine timing cover

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the crack, permanently sealing it to prevent any further oil escaping

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Case Study Details

The delivery truck belonged to a milk company in Puerto Rico. Oil was discovered to be leaking from the timing cover of the vehicle’s 466 International engine. Once opened, a hairline crack was discovered in the casing.

A replacement cover would have cost $1000. Delivery of the part was estimated to take up to a week. The company needed the truck to be back in service as soon as possible and so they sought a faster, more cost-effective repair.

The opened timing cover during inspection
A crack developed in a 466 International Engine timing cover which then underwent repair with Industrial Metal Epoxy Paste
A hairline crack discovered in the centre of the metalwork

Sylmasta technicians were able to formulate a repair method for the timing cover, involving a degree of preparation followed by the use of Industrial Metal Epoxy Paste. Instructions were sent to the engineer, who had been asked to find a solution by the company.

Before the application of the paste began, Sylmasta recommended that the ends of the crack were drilled. This was to relieve stress concentration and prevent the crack from spreading further.

Repair instructions, showing the V-shaped grooves to be cut along the top and bottom of the crack and the overlap of epoxy paste

A coarse 3-square file was used to cut a V-shaped groove along the length of the crack, widening the gap in both the top of the metalwork and underneath. This increased the available surface area to which Industrial Metal could bond. The V-grooves were then degreased to remove contamination.

Part A and Part B of Industrial Metal were mixed in the instructed ratio. A spatula was used to force the paste into the crack, completely filling both V-grooves. The paste was also overlapped by 20mm either side of the crack to ensure full adhesion.

Crack in 466 International timing cover undergoes repair using Industrial Metal Epoxy Paste
The crack seamlessly filled in and repaired once Industrial Metal had cured

Industrial Metal has a work time of 60 minutes, allowing it to be carefully applied to the crack without the worry of premature curing. A full cure was achieved in 24 hours, after which the paste set to form a solid metallic material which seamlessly filled and repaired the crack.

One day after the application had been completed, the delivery truck was back on the road with the timing cover no longer leaking. The company were very pleased with the technical advice offered by Sylmasta, the speed and ease with which they had been able to complete the repair – and obviously, the cost saving.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Reinforcement of Weakened Pipe Elbow Joint on 100mm 22 bar Sulphuric Acid Line

A 100mm pipe elbow undergoes reinforcement after the sulphuric acid line it was part of was found to have degraded by 21mm thickness

Chemical romance – the repair and reinforcement of a sulphuric acid line pipe elbow found to have degraded in thickness by 21mm

A pipe elbow on a 100mm sulphuric acid line operating under 22 bar pressure which had degraded from 22mm thickness to just 1mm undergoes urgent repair and reinforcement in Saudi Arabia.

Case Study Data

Site
Petrochemical Refinery
Location
Saudi Arabia
Repair Type
Pipeline reinforcement
Defect
Weakened elbow joint on a 100mm sulphuric acid line

Products Used

Industrial Metal Epoxy Paste
Applied to the elbow joint to strengthen it via the creation of a shell resistant to corrosion and chemical attack

SylWrap HD Pipe Repair Bandage
Applied over Industrial Metal for further reinforcement by encompassing the elbow with a rock hard protective sleeve and increased hoop strength

Case Study PDF

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Case Study Details

The petrochemical refinery produces over 140 million barrels of petroleum products and 5 million tons of petrochemical products every year, including naphtha, kerosene, gasoline, diesel and fuel oil.

During a routine inspection, a 100mm sulphuric acid line operating under 22 bar pressure was found to have degraded to only 1mm thickness from 22mm on an elbow joint. This required urgent attention before the line failed.

The scale of production at the site meant that the petrochemical company were keen not to have to shut down the line to replace the weakened section, as this would severely impacted on output.

They therefore needed a flexible method of reinforcement for making an effective repair to the elbow on the sulphuric acid line which, for example, a pipe repair clamp would not have been capable of.

A pipe elbow in a line carrying sulphuric acid undergoes repair using Sylmasta Industrial Metal Epoxy Paste
The elbow joint was reinforced using Industrial Metal Epoxy Paste

The petrochemical refinery consulted an engineering company with whom Sylmasta work with in the region, and they decided to apply Industrial Metal Epoxy Paste to the elbow to strengthen it.

Industrial Metal is reinforced with corrosion-resistant metal platelets which provide excellent protection against corrosion and chemical attack, creating a tough outer shell around pipes and structures.

Industrial Metal Epoxy Paste is applied to a pipe elbow joint in Saudi Arabia to reinforce a weakened 100mm sulphuric acid line
Industrial Metal applied to the elbow using a putty knife

The epoxy paste was spread over the area requiring reinforcement using a putty knife. The 60 minute work time allowed for a large quantity of paste to be mixed and applied without the threat of premature curing, an especially important consideration given the hot climate.

If the remaining 1mm degraded further and the original line was breached, its contents would now be contained by a casing with high chemical and corrosion resistance surrounding the elbow provided by the cured Industrial Metal.

To further reinforce the elbow, SylWrap HD Pipe Repair Bandage was applied over the Industrial Metal. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in 30 minutes.

It provided an impact resistant layer of protection over the elbow, increasing the hoop strength of the line until such time as a replacement could be conveniently carried out.

Repair completed with SylWrap HD for increased hoop strength

Whilst the reinforcement took place, the pressure was reduced to 8 bar with only a minor amount of disruption to operations at the site. 24 hours after the repair had been completed, the line was restored to its normal 22 bar pressure..

The petrochemical refinery were delighted with the ease and speed of repair made possible by Sylmasta. Regular inspections of the line showed that there had been little to no decrease in the strength of the repair over two years later.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Industrial Metal Repairs a Large Gouge to Refurbish a Drill Base Stand

Industrial Metal used to repair a severely damaged drill base stand

Drill and fill – the repair and refurbishment of a badly damaged second-hand drill base stand

An engineer refurbished a second-hand drill base stand at a fraction of the cost of buying new, using Industrial Metal Epoxy Paste to repair a large gouge caused by the previous owner’s misuse.

Case Study Data

Repair Type
Metal repair and refurbishment
Defect
Large gouge in a drill base stand

Products Used

Industrial Metal Epoxy Paste
Epoxy paste used to fill the significant gouge suffered by the drill base

Case Study PDF

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Case Study Review

The stand was suffering from a significant gouge where the drill had frequently been allowed to penetrate the base by the previous owner, who as a result had subsequently decided to sell the stand.

It was otherwise in good condition, meaning that if the engineer who bought the stand could refurbish it, then he would have a working second-hand drill base at a fraction of the cost of purchasing new stock.

After consulting Sylmasta, it was decided that Industrial Metal Epoxy Paste would be the most suitable material for filling in the gouge and returning the base to close to its original state.

A large crack in a drill base stand which required a repair to refurbish the stand to its original state
The large gouge in the drill base stand requiring repair

Industrial Metal is thixotropic, meaning it will not sag. It is virtually odourless, with no unpleasant smell compared to other epoxy pastes.

It is temperature resistant to 130°C and reinforced with corrosion-resistant metal platelets, giving it a smoother finish than regular epoxy repair pastes when machined.

The gouge in the stand requiring repair had penetrated right through the base. To prevent the Industrial Metal falling onto the floor as it was applied, a wooden plate was placed underneath the gouge.

Wooden plates fashioned to assist the application of Industrial Metal

Further wood was used to ensure that the necessary gaps included as part of the base’s design did not inadvertently become filled by the epoxy paste.

Before using Industrial Metal, the drill base had to undergo a degree of preparation. All traces of rust and grime were removed from the surface, which was then roughed up using abrasives.

Industrial Metal was applied as soon as the preparation stage was complete. The epoxy paste was pushed into the gouge using a hand tool, with the work time of 60 minutes allowing more of the paste to be mixed and applied without the threat of premature curing.

Industrial Metal Epoxy Paste applied to fill in a large crack in a drill base stand repair and refurbishment
Industrial Metal applied to fill the gouge
Completed repair of a drill base stand using Industrial Metal Epoxy Paste
The completed repair was sanded down to an ultra-smooth finish

A full cure was achieved in 24 hours, after which the surface of the drill stand was sanded down to provide an ultra-smooth finish which was seamless with the rest of the base. The rebuild using epoxy paste had been a complete success.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com