Polyurethane Foam Field Joint Infill Systems - PIH - Pipeline ...

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Services to the Pipeline Industry P ipeline Induction Heat Ltd (PIH), a CRC Evans Company is a contracting company specialising in the onsite application of anti-corrosion coatings, heat treatment and other support services during construction of onshore and offshore oil, gas and product pipelines. The pipeline industry is characterised by rapid advances in automatic welding and factory-applied linepipe coating technologies. Anticipating these trends requires PIH to undertake innovative research and development to provide practical solutions, which satisfy these stringent new standards. This has resulted in an expansion from PIH's traditional induction heating business, into diverse activities involving the site application of sophisticated pipeline joint anti-corrosion, thermal insulation and infill coating systems. As the most experienced independent field joint coating contractor, PIH fully understands the necessity for working alongside both main contractors and owners to provide a total project service for field joint coating of their pipelines. On time, on budget and to specification are key parameters in the PIH business philosophy. However, this is never allowed to overshadow the primarily important factor of health and safety on construction worksites. Operating a fully BSI accredited health and safety management system, PIH places primary focus on achieving zero accidents both in the field and throughout the business operation. "PIH aims to provide the best specialist pipeline 'field joint' service worldwide, offering a complete end-to-end package of total in-house design, build and supervisory control to today's onshore and offshore pipelay contractor.” As concern within the pipeline industry becomes ever more focussed on environmental issues, PIH has worked hard to develop new technologies and application systems, which are more efficient, reduce waste and pose less of a threat to the environment. Collaborating with the main contractors, PIH has developed automatic coating machines that reduce over spray and coating material losses during application hence reducing if not eliminating any environmental impact. Similarly, PIH automatic tape wrap systems reduce the use of powder technology so greatly reducing wastage and enhancing operator safety. For more than two decades PIH has worked with more main contractors than any other independent field joint coating contractor. PIH has successfully completed millions of pipeline field joints on every continent working in every environment. Using skills and experience now gained by the UK workforce and its partners, PIH intends to face the future confident in their ability to drive the industry forward with new and innovative technology in a technology driven sector. Safer and more efficient field joint coating systems being constantly developed and implemented on projects worldwide with the aim of providing clients with fully compliant solutions while maintaining PIH as the world's pre-eminent field joint coating specialist. “We strive to provide the most reliable, cost effective solutions within the rigorous time scales demanded of the industry, whilst maintaining the highest quality results.”
The Polyurethane Foam Infill System I nfilling the field joint void on concrete weight coated pipe has traditionally been affected by pouring hot marine mastic into a mould around the joint. The mould is usually left in place when over-boarded by the laybarge. Since this mastic is poured hot and is hazardous to handle PIH has adapted an alternative PU based infill system offering improved HSE security as well as the following beneficial features : • No heat sources are necessary (process at ambient temperatures) • Commercially attractive • Rapid cycle times • Re-usable or expendable / disposable (metallic or plastic) mould systems • Compact, reliable application equipment Polyurethane foam infill advantages include : • Compatibility with all conventional anti-corrosion field joint coating systems • ODP – zero category formulation (no ozone damaging CFC solvents) • Water blown • No solvents required - all equipment is air-purged • A range of foam densitys are available (6-10 lb / cu ft) typically The material most commonly used by PIH is ‘Cellafoam-150’. It is a custom-designed high density polyurethane foam (HDPF) with a typical moulded density between 90 kgs per cubic metre (Cellafoam – 150/6) and 160 kgs per cubic metre (Cellafoam – 150/10) un-saturated. Formulated specifically for pipeline field joint applications, the Cellafoam-150 system develops a rigid, open cell structure. Upon immersion, the open cells will absorb water, thereby increasing in overall density to approximately 1025 kgs/m 3 (similar to seawater itself). The low-viscosity product formulation of the ‘Cellafoam 150’ system allows ‘free-flow’ of chemicals, to assure quick and complete filling of the mould, within the cycle times demanded by today’s laybarge operators. The infilling system can incorporate reusable or disposable moulds. Reusable moulding is used in conjunction with a cardboard fibre liner, to create a superior high strength composite skin. This system will allow the demoulded field joint to pass over the laybarge rollers and stinger without damage due to the fibre liner becoming embedded in the surface of the foam creating a resilient outer skin to the joint. Disposable plastic or metal moulds can be used as required by environmental and operational demands. The application equipment is neat and compact consisting of little more than 2 holding tanks, small pumping equipment and dispensing hoses and nozzles. The basic application for all systems can be summarised as follows : • Fibre liner is applied to the joint and secured in place • The mould is centralised over the field joint and secured in place using temporary or permanent strapping (depending on whether re-usable or disposable moulds are being used). • The infilling nozzle is applied to an opening in the mould and a fixed volume of material is metered from the pumping system into the void. • The PU foam material is allowed to expand to fill the void and cure prior to mould removal (in a re-usable moulding system) or prior to pipe movement over the rollers (in a disposable system).
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Polyurethane Foam Field Joint Infill Systems - PIH - Pipeline ...

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