Case study: cold repair of corroded pipeline in ATEX-Zone
In the demanding environment of the North Sea, a significant challenge arose: a leak in a pipeline at a major offshore facility within the Benelux region. The pipeline, carrying aggressive air, had succumbed to corrosion, leading to a minor but concerning leakage. Operating within an ATEX zone, where explosive atmospheres are a constant risk, necessitated a repair approach that was both safe and compliant with stringent regulations.
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The challenge:
The presence of aggressive air as the pipeline’s medium had accelerated corrosion, compromising the integrity of the system. Traditional repair methods involving hot work were not viable due to the explosive potential within the ATEX zone. A solution was required that could address the corrosion and leakage without introducing ignition risks.
The solution
ATEX-tools and Perspect renowned for their expertise in leakage sealing within ATEX zones, devised a meticulous seven-step cold repair procedure:
- Surface Preparation: The entire circumference of the affected area was roughened using ATEX-certified tools, specifically the A-0004 (Little Papa) and A-0107. These tools are designed to operate safely in explosive environments, eliminating the need for hot work permits.
- Degreasing: A thorough cleaning of the surface was performed using Belzona 9111 to ensure optimal adhesion of the repair materials.
- Mixing Belzona 1111: The high-performance epoxy-based composite, Belzona 1111 (Super Metal), was prepared. This material is ideal for metal repairs, offering excellent mechanical properties and chemical resistance.
- First Coat Application: A base layer of Belzona 1111 was applied with a short-bristled brush to the prepared surface, ensuring complete coverage.
- Reinforcement: A Belzona 9341 reinforcement sheet was embedded into the wet first coat to enhance the repair’s structural integrity.
- Second Coat Application: An additional layer of Belzona 1111 was applied over the reinforcement, creating a smooth and uniform finish.
- Curing: The repair was allowed to cure at 20°C for 24 hours, achieving full mechanical strength without the need for heat.
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Outcome:
This cold repair approach successfully restored the pipeline’s integrity without the hazards associated with hot work. The use of ATEX-certified tools and Belzona’s cold-curing materials ensured compliance with safety regulations and minimized operational downtime
Why choose Allmet Safety tools?
For asset owners and contractors operating in hazardous environments, Allmet Safety Tools offers unparalleled expertise in safe and efficient repair solutions. Our services include both rental and purchase options for ATEX-certified tools, catering to diverse operational needs.
Explore our solutions
- Surface Treatment in ATEX Zones: Utilize our ATEX-certified tools to safely and effectively prepare surfaces in explosive atmospheres, ensuring compliance and optimal coating adhesion.
- Spot Repair in ATEX Zones: Address localized coating damages promptly with our specialized equipment, designed to operate safely within ATEX environments, thereby extending the lifespan of your assets.
- Corrosion Removal in ATEX Zones: Combat corrosion efficiently using our non-sparking tools, which are ideal for maintaining structural integrity without the risks associated with traditional methods.
- Paint and Coating Removal in ATEX Zones: Safely strip away old paints and coatings in hazardous areas with our compliant tools, facilitating necessary maintenance while adhering to safety standards.
Contact us today
Ensure the safety and reliability of your assets with Allmet Safety Tools‘ expert services. Contact us to discuss how our solutions can meet your maintenance and repair needs.