Henkel's main manufacturing plant in Düsseldorf is criss-crossed by 18 kilometres of pipe bridges and 300 kilometres of pipelines. Over time, sections had become corroded and their repair was subcontracted to the company Xervon. In order to repair leaks quickly, safely and sustainably Xervon used Henkel's recently introduced LOCTITE Composite Repair System and, in so doing, created a reference site for the process.
This innovative system allows corroded pipes to be repaired without interrupting operations, avoiding the high costs associated with unplanned shutdowns. It effectively eliminates the need for pipe sections to be replaced and substantially extends the lifetime of the repaired pipework system.
Carsten Sperlich, who heads the technical infrastructure department at the Düsseldorf site comments: "Our target is to extend the service life of pipes by 20 years and we are confident the LOCTITE Composite Repair System will last far beyond that."
The first step is cleaning. This is done by sandblasting the surface of the defective pipe section to a cleanliness level of SIS SA 2.5. The blasting also produces a roughness of 75 micrometres peak-to-valley height in the steel surface and the resulting surface texture ensures physical anchoring in addition to the adhesive bonding with the coating material.
Next, LOCTITE SF 7515 is applied as a short-term corrosion inhibitor to prevent flash rust. The pipe is then wrapped with several layers of the high-strength, glass-carbon fibre tape, LOCTITE PC 5085, which has been impregnated with the two-part epoxy resin, LOCTITE PC 7210. Finally, several layers of topcoat, LOCTITE PC 7255, are applied as corrosion protection.
The repair system has been certified by DNV CL in accordance with the global quality standard ISO 24817. This standard defines the criteria for the use of composite systems in petrochemical, oil and gas industries. The method has also been approved by Lloyds Register - in conformity with ASME PCC-2 standard - and by TÜV Rheinland.
Henkel's Bernd Hammer, Global Market Development Manager, Adhesives Technologies, for Oil & Gas and Refineries advises: "Certification is a very complex procedure. We are the only supplier in the market that is certified by the three inspection authorities and this gives our customers the assurance that the system really delivers what it promises."
Xervon, one of a growing number of select service providers that make up the Henkel Certified Applicator network across Europe, underwent an extensive qualification process to achieve the status. The company's Managing Director, Thomas Peter Wilk, adds: "I consider the LOCTITE Composite Repair System to be an excellent solution and our joint project at Henkel's Düsseldorf site is an excellent way to demonstrate its effectiveness to industry."
The LOCTITE Composite Repair System is now being used widely in refineries, petrochemical plants, power plants and water treatment systems. Core applications are in the oil and gas industry where the system can be used in all upstream, midstream and downstream areas. There are currently a high number of production plants across the world that have reached an age when they require general overhaul and this has prompted considerable interest in the capability of this LOCTITE repair system.
Henkel's Bernd Hammer concludes: "That's why it was so important to apply the system in our own manufacturing plant in Düsseldorf. It gives us an easily accessible reference site for potential customers and also allows us to monitor its effectiveness over the long term. This way everyone can see for themselves the level of quality this repair provides."
More information about the LOCTITE Composite Repair System can be found at www.loctite.co.uk.