Technical Description PDF

CHAPTER 1
Technical Description
CONTENTS
1. INTRODUCTION ...............................................................................................................1
2. TECHNICAL SPECIFICATION .............................................................................................2

2.1. STEEL PIPE DIMENSIONS ......................................................................................3
2.2. TYPES OF PIPES TO BE HANDLED .........................................................................3
2.3. PIPE TOLERANCES ...............................................................................................4
2.4. PIPE SURFACE CONDITIONS .................................................................................4
2.5. POWER AND UTILITIES.........................................................................................5
2.6. OPERATING CONDITIONS .....................................................................................6
2.7. APPLICATION METHOD ........................................................................................6
2.8. PRODUCTION CAPACITY ......................................................................................7
3. WORKING PRINCIPLE.....................................................................................................10
3.1. PIPE RACKS .......................................................................................................14
3.2. STOPPER, LOWER-IN AND KICK-OUT ..................................................................14
3.3. INSPECTION STATIONS .......................................................................................14
3.4. DUST FILTERS ...................................................................................................14
3.4.1. External blaster dust filter ....................................................................15
3.4.2. Blow-out station dust filter ..................................................................16
3.4.3. FBE unit dust filter...............................................................................17
3.4.4. Pipe end cleaning station dust filters ...................................................18
3.5. GAS-FIRED HEATERS .........................................................................................19
3.6. BLASTING CONVEYOR .......................................................................................21
3.7. EXTERNAL BLASTER .........................................................................................23
3.8. BLOW-OUT STATION .........................................................................................24
3.9. DIABOLO CONVEYOR ........................................................................................25
3.10. COATING CONVEYOR ........................................................................................26
3.11. COUNTER FLOW FAN .........................................................................................27
3.12. EXTERNAL PIPE WASH UNIT...............................................................................28
3.13. CHROMATE APPLICATION UNIT .........................................................................29
3.14. FBE APPLICATION UNIT ....................................................................................30
3.15. ADHESIVE AND COATING LAYER EXTRUSION ....................................................32
3.16. PRESSURE ROLLER SYSTEM AND WELD SEAM COMPENSATION ..........................33
3.17. QUENCH ............................................................................................................34
3.18. HOLIDAY DETECTOR .........................................................................................34
3.19. PIPE END CLEANING STATION ............................................................................34
3.19.1. Rotation units .......................................................................................34
3.19.2. Brush units ...........................................................................................35
INDEX .....................................................................................................................................36
TECHNICAL DESCRIPTION Project 355
CHAPTER 1. TECHNICAL DESCRIPTION
1. INTRODUCTION
This manual contains all information in order to operate and maintain the:
EXTERNAL PIPE BLASTING AND COATING PLANT
Pipe diameter range 123/4" to 48" (324 mm to 1219 mm).
Manufactured by: Selmers B.V.

Biesland 3
1948 RJ BEVERWIJK
P.O. Box 628
1940 AP BEVERWIJK
THE NETHERLANDS
Designed for: Servicios Condumex, S.A. De C.V.

Miguel de Cervantes Saavedra No. 255, Col. Granada
11520 MEXICO
MEXICO
Year of manufacture: 2007
Part 1 - book 1 Chapter 1 - Page 1

2. TECHNICAL SPECIFICATION
The equipment is designed to the specifications as described in this chapter.
ATTENTION: The equipment is not designed or intended for any

other use than described in this manual.
Doing so can cause severe damage to the equipment
and / or severe injury to any person near the
equipment.
The equipment shall therefore only be used to handle steel pipes which comply with the
standards and dimensions stated in paragraph 2.1 to 2.4. When steel pipes with a different
size or standard are to be coated, contact SELMERS to investigate the possibilities of altering
the equipment.
It is not possible to handle pipes made from any other material than steel.
It is not possible to handle pipes that are already (partially) externally coated.

2.1. STEEL PIPE DIMENSIONS
Applied diameter range:

- minimum: 123/4" (324 mm)
- maximum: 48" (1219 mm)
Pipe wall thickness:

3
- minimum: /8" (9.5 mm)
- maximum: 1" (25.4 mm)
Pipe length:
- minimum: 8 metres
- maximum: 12 metres
- Pipes shall be supplied to the plant in batches of equal length and diameter.
Pipe weight:
- maximum: 750 kg/m
- maximum: 9000 kg/12m pipe
2.2. TYPES OF PIPES TO BE HANDLED

- Electrical resistance welded (ERW) pipes.
- Seamless pipes.
- Longitudinal submerged arc welded pipes.
- Spirally submerged arc welded pipes.
Pipes shall conform to API Specification 5L.

2.3. PIPE TOLERANCES

The dimensions, weights and lengths of pipes shall be conform section 6 of API Specification
5L.
Straightness:
The curvature of the pipes shall not exceed 1.5 mm per 1 metre of pipe length.
Roundness:
The roundness shall be within ± 1% of the outside pipe diameter.
Weld seam:
The weld seam should have a regular shape with a smooth transition to the pipe and shall not
have sharp edges. The height of the reinforcing groove and welds shall not exceed the
following:
For wall thickness up to 8 mm: max. 2.5 mm

For wall thickness of 8 and up till 14 mm: max. 3.0 mm
For wall thickness of 14 and up: max. 4.0 mm
2.4. PIPE SURFACE CONDITIONS

Pipes after transportation from the manufacturing plant and possible storage in an open area
are subject to coating.
The external and internal surface of the pipes supplied to the cleaning line may be
contaminated with rust, mill-scale and normal dust load. In case of excessive dust and /or
sand or other contaminations on the inside & outside of the pipes, the pipes should be cleaned
prior to entering the plant.
The surfaces of the pipes shall be free from cracks, dents, tears, lapse, salts, oil, grease and
loose water.
The pipe shall have an equal body temperature, which may vary from +10°C to +40°C, but
shall in any case be +5°C above the ambient dew point temperature.
The cleanliness degree of the outside surfaces of the pipes in the initial state shall be A,
according to the rates of Standard SIS 055900 (Sweden) or ISO 8501.

2.5. POWER AND UTILITIES
Electric power:
- voltage: 460 V +/- 5% AC
- frequency: 60 Hz +/- 1%
3 phases with neutral and earth conductor.
Natural gas:
- pressure: 1 - 2 bar
- calorific value: 33580 kJ/mn3
Compressed air:
- pressure: 6 to 7 bar
- required general quality: According to ISO 8573/1: class 3 (dirt content)
class 4 (water content)
class 3 (oil content)
Required quality for epoxy powder unit:

- water content: max. 0.117 g/m3
- oil content: max. 0.01 mg/m3
- temperature: max. +30 °C
- pressure dew-point: - 40 °C
Which is according to ISO 8573/1: class 2 (dirt content)
class 2 (water content)
class 1 (oil content)
Cooling water:
- required quality: temperature: +10 °C to +20 °C
hardness as CaCO3: 30 to 500 ppm
alkalinity as CaCO3: max. 500 ppm
total dissolved solids: 1000 ppm
chlorides: max. 125 ppm
sulphates: max. 125 ppm
pH: 7 to 9
conductivity: max. 800 µS/cm
Reverse osmosis water:

- conductivity: max. 30 µS/cm

Hydraulic oil:
- required general quality:
According to ISO 4406: class 18/15
(130,000 to 250,000 particles > 5µm and 16,000 to 32,000 particles > 15µm)
2.6. OPERATING CONDITIONS

The equipment is to be erected inside a building.
Climatological conditions inside building:

Minimum temperature: + 10 °C
Maximum temperature: + 40 °C
Max. relative humidity: 90%
Climatological conditions outside building:

Minimum temperature: + 5 °C
Maximum temperature: + 42 °C
Max. relative humidity: 90%
Design wet bulb temperature: 28 °C
2.7. APPLICATION METHOD
External blasting:
Blasting to - cleanness ASA 2.5
- roughness 50 - 70 micron
External single layer FBE-coating:

The coating method is in accordance with CAN/CSA Z245.20-02
Coating thickness: approx. 500 microns

External 3-layer PE-coating:

The coating method is in accordance with the following standard:
- DIN 30670 (polyethylene coating of steel tubes, fittings and matching pieces.)
Coating thickness:
- Epoxy primer: - nominal 150 microns
- minimal 60 microns
- Adhesive layer: nominal 250 microns

minimal 180 microns
- Total coating layer thickness according to DIN 30670 (standard coating):

Pipe o.d.: Standard thickness:
Up to.101 mm max. 1.8 mm
101 - 250 mm max. 2.0 mm
251 - 500 mm max. 2.2 mm
501 - 800 mm max. 2.5 mm
801 and higher max. 3.0 mm
It is possible to produce a reinforced coating of max. 3.7 mm at reduced production capacity.
2.8. PRODUCTION CAPACITY

The production design has been based on working hours of 2000 hours per year when
working in 1 shift of 8 hours per day, 5 days per week for 50 weeks a year.
The equipment is capable to be operated in two shifts per day, provided that proper
maintenance & cleaning is carried out at regular intervals.
The theoretical average production capacity of the plant, based on a pipe length of 12 metres
and an initial pipe rust degree A (according to SIS055900 standard) and under mentioned
conditions, is as follows:

External blasting and single layer FBE coating:
Steel Thickness
Pipe diameter Design capacity
wall thickness FBE layer
[inch] [mm] [mm] [µm] [m2/hr]
≥ 12" ≥ 324 9.525 500 250
≥ 14" ≥ 356 12.7 500 275
≥ 16" ≥ 406 15.875 500 300
≥ 18" ≥ 457 19.05 500 325
≥ 20" ≥ 508 19.05 500 350
≥ 24" ≥ 610 19.05 500 350
≥ 32" ≥ 813 19.05 500 350
≥ 36" ≥ 914 19.05 500 350
≥ 40" ≥ 1016 19.05 500 350
≥ 42" ≥ 1067 19.05 500 350
48" 1219 19.05 500 350
External blasting and 3-layer HDPE coating:
Total thickness
Steel Design capacity
Pipe diameter 3-layer
wall thickness
HDPE coating
[inch] [mm] [mm] [mm] [m2/hr]
≥ 12" ≥ 324 9.525 2.2 250
≥ 14" ≥ 356 12.7 2.2 275
≥ 16" ≥ 406 15.875 2.2 300
≥ 18" ≥ 457 25.40 2.2 300
≥ 20" ≥ 508 25.40 2.5 300
≥ 24" ≥ 610 25.40 2.5 300
≥ 32" ≥ 813 25.40 3.0 300
≥ 36" ≥ 914 25.40 3.0 300
≥ 40" ≥ 1016 25.40 3.0 300
≥ 42" ≥ 1067 25.40 3.0 300
48" 1219 25.40 3.0 300

The capacity rates are based on the following conditions:

- A good quality and straightness of the pipe
- A good quality, -shape, -height and -transition of the pipe weld seam
- Usage of suitable abrasives, usage of a suitable (West European) coating materials
- Plant operation by qualified and skilled personnel
- Proper maintenance of the plant
- Local operational conditions.
Plant capacity does not include time required for handling of pipes on the racks / in the plant
and the logistics to take the pipes into and out of the factory.
Production capacity will reduce if pipes are oval and/or not straight or shorter than 12 metres.
Reference Materials:
Abrasive material: Wheelabrator-Allevard or equivalent
Epoxy coat material: Jotun, 3M, BASF, BitumeSpeciaux, Akzo or equivalent
Adhesive & PE material: Basell, Dupont, MPB, Borealis, Borouge, Elf Atochem or
equivalent

3. WORKING PRINCIPLE
The external blasting section consists of the following parts:
1 Two inbound pipe racks

2 A blasting conveyor
3 A gas-fired preheater
4 An external blaster with dust filter
5 Two intermediate pipe racks
6 A blow-out station
7 An inspection station
8 A return diabolo conveyor
The numbers refer to Figure 1:

Figure 1: External blasting section

The external coating section consists of the following parts:
9 A coating conveyor
10 An external pipe wash unit
11 A chromate application unit
12 Two gas-fired main heaters
13 An FBE application system
14 A 3-layer PE/PP application system
15 A quench with cooling tower
16 A holiday detection station
17 A pipe end cleaning station
18 An inspection station
19 Two outbound pipe racks
The numbers refer to Figure 2:

Figure 2: External coating section.

3.1. PIPE RACKS

The pipe racks are used create buffer space for the pipes between two stations, and are used
to move pipes from one station to the next. To prevent the coating from getting damaged, the
upper surface of the pipe racks after the coating conveyor is padded.
3.2. STOPPER, LOWER-IN AND KICK-OUT

The stopper, lower-in and kick-out are hydraulically operated. The stopper is used to move
one pipe at a time from the pipe racks to the lower-in. The lower-in places the pipe on the
conveyor or on the rotation units. The kick-out lifts the pipe from the conveyor or the rotation
units and moves it to the pipe racks.
3.3. INSPECTION STATIONS

Inspection stations are placed after the blow-out station and after the pipe end cleaning
stations. Each pipe inspection station consists of two rotation units and an inspection
walkway. Here the blasted surface or the coated surface can be checked.
3.4. DUST FILTERS

Dust filters are placed near the external blaster cabin, the blow-out station, the FBE
application unit and on the pipe end cleaning units.
The dust filter sucks dust filled air away and filters the air from dust and small particles.
The dust filters are equipped with replaceable filter cartridges or filter bags. A ventilator
connected to the dust filter sucks the dust filled air through the filter cartridges or filter bags.
The dust consists of rust, dirt, coating remains etc, which is unusable and is to be disposed of.
At the FBE application unit, the dust consists of reusable epoxy powder. During the filtering
process, dust accumulates on the outside of the filter cartridges or filter bags. In order to clean
the filter cartridges or filter bags, a compressed air pulse is regularly blown in the opposite air
flow direction through the filter cartridges or filter bags. In this way, the accumulated dust
falls off the filter cartridge or filter bag down to the hopper. Depending on the type of dust
filter, only one filter cartridge at a time is cleaned in this way, or a row of filter cartridges or
filter bags is cleaned in this way, thus assuring a continuous functioning of the dust filter. The
air pulse is released by a diaphragm valve, mounted just behind each filter cartridge, or on a
blowpipe towards the filter cartridge or filter bags. A timer controlled solenoid valve
activates the diaphragm valve.

At the external blaster dust filter, one row of eight filter cartridges at a time is cleaned by one
air pulse.
At the blow-out station dust filter, one row of four filter cartridges at a time is cleaned by one
air pulse.
At the epoxy powder unit dust filter, one row of eight filter bags at a time is cleaned by one
air pulse.
At the pipe end cleaning station dust filter, one filter cartridge at a time is cleaned by one air
pulse.
3.4.1. External blaster dust filter
Figure 3: Working principle external blaster dust filter.

The blaster dust filter is used to clean the abrasive, and is connected to the sieve and the
blaster cabin. The ventilator of this dust filter is mounted directly on top of the dust filter
cabin. This dust filter is equipped with 32 filter cartridges, which are placed vertically in the
cabin.
The dust consists of unusable material and is collected in a dust container mounted under the
hopper.
3.4.2. Blow-out station dust filter
Figure 4: Working principle blow-out station dust filter.
The blow-out station dust filter is used to extract dust and abrasive remains from the pipe
during the blow-out cycle. The abrasive and heavy dust is separated from the air in the
labyrinth, and falls down into a drawer below the cabin. Only dust-filled air moves on
towards the dust filter.
The ventilator of this dust filter is mounted directly on top of the dust filter cabin. An air flow
regulating valve is mounted directly below the ventilator. This dust filter is equipped with
eight filter cartridges, which are placed vertically in the cabin.
The dust consists of unusable material and is also collected in the drawer below the cabin.

3.4.3. FBE unit dust filter
Figure 5: Working principle FBE unit dust filter.
The epoxy powder unit dust filter is used to extract oversprayed epoxy from the spray cabin.
The ventilator of this dust filter is mounted on the floor and connected with a duct to the dust
filter cabin. This dust filter is equipped with 96 filter bags, which hang horizontally in the
cabin.
The dust consists of usable epoxy powder, which is transported back to the fluid bed by a
transport screw.

3.4.4. Pipe end cleaning station dust filters
Figure 6: Working principle pipe end cleaning station dust filter.
This dust filter is used to extract brushed off coating during brushing.
The ventilator of this dust filter is mounted directly on top of the dust filter cabin. An air flow
regulating valve is mounted directly below the ventilator. The dust filter is equipped with
four filter cartridges, which are placed vertically in the cabin.
The dust consists of unusable material and is collected a dust container mounted under the
hopper.

3.5. GAS-FIRED HEATERS

The heater consists of a heater housing, in which the gas-fired burners are mounted. The
heater before the blaster is equipped with two burners, the first heater in the coating conveyor
is equipped with four burners, the second heater in the coating conveyor is equipped with six
burners.
Figure 7: Schematic view heater.
The gas is supplied to the heater through the gas supply tube. The gas is filtered and led
through the safety shut-off valve. This valve measures the pressure after the gas pressure
governor, and closes automatically when the pressure increases too much. The gas pressure
just before the safety shut-off valve can be read on a manometer.

Figure 8: Piping diagram.
The gas pressure governor regulates the gas pressure down to a workable pressure for the
burners. A gas bleed tube with a safety relief valve is mounted in the gas supply tube to
reduce temporary pressure surges or sudden pressure increases. A set of two pressure
switches measure the pressure in the gas supply tube and give signal to the control cabinet.
Gas supply to the gas manifold is controlled by a motorised valve. Opening and closing of
this valve is controlled by the control cabinet. After this valve, a pressure switch is placed in
the gas supply tube in order to execute a tightness test of the motorised valve before starting
the burners. A gas bleed tube with a solenoid valve is mounted after the pressure switch, to
relieve the pressure from the gas piping before executing the tightness test.
The gas manifold transports the gas to the burners. The pressure towards the gas manifold can
be read on a manometer in the gas supply tube. The tube toward each burner is equipped with
a manually operated valve and a solenoid valve. The solenoid valve is opened when the
burner is used. Next, an air/gas pressure ratio controller is mounted in the tube. This
controller measures the air pressure and adjusts the gas pressure to create a 1:1 ratio. A
manually operated pressure regulating valve is mounted after the ratio controller in order to
choke the gas pressure. The pressure after the pressure regulating valve can be read from a
manometer. The gas is led to the burners, where it is mixed with air.

The air is supplied by a blower (ventilator). Air supply to the air manifold is controlled by a
servo motor driven butterfly valve, which is operated from the control panel. The minimum
pressure in the air supply tube is measured by a pressure switch, which gives signal to the
control panel. The pressure can also be read from a manometer.
The air manifold transports the air to the burners. The tube toward each burner is equipped
with a manually operated butterfly valve. After the butterfly valve, the air pressure is
measured by the pressure ratio controller. The pressure can also be read from a manometer.
Subsequently, a manually operated pressure regulating butterfly valve is mounted in the tube
just before the burner, in order to choke the air pressure towards the burner. The pressure just
after the pressure regulating butterfly valve can be read from a manometer. The air is lead to
the burners, where it is mixed with gas.
The burners are ignited by spark plugs, activated by an ignition transformer. An ionisation
electrode is integrated in each burner to detect the presence of a flame. The temperature in the
heater is measured and displayed on the control panel.
3.6. BLASTING CONVEYOR

The blasting conveyor consists of a row of several wheel pairs. The conveyor wheels are set
to an adjustable angle, to transport the rotating pipe. To do this, the wheels are mounted on
rotating wheel supports. The conveyor is mechanically divided in several sections.
Figure 9: Schematic top view blasting conveyor, wheels at 90 degrees.
The wheel supports on each side are mutually coupled with angle adjustment connecting
rods. One wheel support is also connected to a motor driven angle adjustment spindle. When
the spindle length is changed, subsequently all coupled wheel supports are rotated over an
equal angle. Each side has its own angle adjustment spindle, but both spindles run
simultaneously to keep both wheels rows at the same angle.

In order to handle the entire pipe diameter range, the distance between the wheels is
continuously variable. The wheels are mounted on slide plates, which are positioned with the
aid of mutually coupled centre adjustment spindles. The spindles of one conveyor section are
connected to one motor with the centre adjustment drive shaft. When the centre adjustment
motor runs, all spindles in one section are driven by the centre adjustment drive shaft. This
makes both centre adjustment slide plates move simultaneously over an equal distance.
Part of the wheels of the conveyor are motor driven. The motors are frequency controlled in
order to let the pipe rotate at the required speed. The rotating speed of the wheels and the
angle of the wheels determine the axial speed of the pipe. The conveyor is electrically divided
in three sections, in order to accelerate incoming and outgoing pipes. The pipes must run
without a gap through the preheater and the blaster. After the blaster, a gap must be created to
kick the pipe out.

3.7. EXTERNAL BLASTER

The blaster consists of a blaster cabin with two blast wheels and a system to collect, clean and
store abrasive. The abrasive is led from the abrasive bunkers to the blast wheels through the
abrasive valves, which dose the amount of abrasive. The abrasive is thrown against the pipe
by the rotating blast wheels. Used abrasive falls down to the bottom of the blaster cabin and
is transported to the elevator housing by the abrasive screw. The abrasive is transported up by
the elevator. It enters the sieve and is separated from pollution by the sieve grate. Next the
abrasive is led through an air flow, which sucks away the lighter particles and dust. The
particles fall down in a collecting pipe. The cleaned abrasive falls down to the bunker and is
ready for reuse. The air is filtered by a dust filter.
Figure 10: External blaster.

3.8. BLOW-OUT STATION

The blow-out station consists of a rotation unit, an air blower and a dust filter.
Figure 11: Side view blow-out station.
The pipe is placed on the rotation unit and is rotated during the blow-out cycle. Due to the
rotation, dust and abrasive comes loose from the pipe surface and is sucked out of the pipe by
the dust filter. Air is also blown into the pipe by the air blower.
The dust and abrasive is sucked away by a movable dust filter. The dust filter is equipped
with a labyrinth, and is mounted on a carriage. The cabin is moved over the pipe end. The air
is first sucked through the labyrinth, where most abrasive and other heavy particles fall down
to the drawer. The dust filled air moves on to the dust filter, where the air is filtered. The dust
falls also down to the drawer.
The air blower is mounted on a carriage. The air blower is equipped with a long blowpipe,
which enters the pipe during the blow-out cycle. When the air blower carriage is at the
reverse end position, the blower runs at a reduced speed, to reduce inconvenience of air
blown into the building. As soon as the air blower carriage is moved towards the pipe, the
blower switches to full speed.

3.9. DIABOLO CONVEYOR

The diabolo conveyor transports the pipe in longitudinal direction, without rotating of the
pipe. The diabolo conveyor consists of a row of diabolo rollers, on which the pipe lies. The
diabolo rollers are driven by an electric motor.
The first section of the diabolo conveyor consists of lifting diabolo rollers, in order to lift the
pipe from the inspection station rotation units. The lifting diabolo rollers are hydraulically
operated.
The approved pipe is stopped halfway and is kicked out towards the coating conveyor.
A rejected pipe is moved back towards the inbound blasting conveyor.

3.10. COATING CONVEYOR

The coating conveyor consists of a row of multiple wheel pairs. The conveyor wheels are set
to an adjustable angle, to transport the rotating pipe. To do this, the wheels are mounted on
rotating wheel supports. The conveyor is mechanically divided in several sections. The
wheels between the first gas-fired heater and the quench are heat resistant and air-cooled.
Figure 12: Schematic top view coating conveyor, wheels at 90 degrees.
Most wheel supports are placed at a fixed position on the skid. The heat resistant wheels on
the skid after the second heater and the first two wheel pairs in the quench are clamped on the
skid and can be repositioned to allow for optimum support of the pipe.
The wheel supports on each side are mutually coupled with angle adjustment connecting
rods. One wheel support is also connected to a motor driven angle adjustment spindle. When
the spindle length is changed, subsequently all coupled wheel supports are rotated over an
equal angle. Each side has its own angle adjustment spindle, but both spindles run
simultaneously to keep both wheels rows at the same angle.
The heat resistant wheels on the skid after the second heater and the first two wheel pairs in
the quench are each equipped with a separate angle adjustment spindle.
In order to handle the entire pipe diameter range, the distance between the wheels is
continuously variable. The wheels are mounted on slide plates, which are positioned with the
aid of mutually coupled centre adjustment spindles. The spindles of one conveyor section are
connected to one motor with the centre adjustment drive shaft. When the centre adjustment
motor runs, all spindles in one section are driven by the centre adjustment drive shaft. This
makes both centre adjustment slide plates move simultaneously over an equal distance.
The heat resistant wheels on the skid after the second heater and the first two wheel pairs in
the quench are each equipped with a separate centre adjustment spindle.

Part of the wheels of the conveyor are motor driven. The motors are frequency controlled in
order to let the pipe rotate at the required speed. The rotating speed of the wheels and the
angle of the wheels determine the axial speed of the pipe. The conveyor is electrically divided
in several sections, in order to accelerate incoming and outgoing pipes. The pipes must run
without a gap through the chromate application unit, the heaters and the coating area. After
the coating area, a gap must be created to kick the pipe out.
3.11. COUNTER FLOW FAN

The counter flow fan is placed near the inbound section of the coating conveyor. The air flow
of the counter flow fan runs through the pipes, thus preventing steam running from the
quench to the inbound section.
Figure 13: Top view counter flow fan.
The counter flow fan creates an air flow towards the pipe and is equipped with a direct
blowing duct and a branch line. When the pipe is moved over the conveyor towards the
coating area, the distance between the pipe and counter flow fan becomes very large.
Therefore, a branch line is made towards a second blowpipe in the inbound section of the
conveyor. Both the direct blowing duct and the branch line are equipped with motorised
valves.
As soon as the pipe has passed the blowpipe, the blowpipe is lifted and the motorised valve
towards the branch line is opened. The motorised valve in the direct blowing duct is closed
and all air blows through the branch line into the pipe.
When the next pipe is about to be placed on the conveyor, the air flow is directed to the direct
blowing duct again and the blowpipe is lowered.

3.12. EXTERNAL PIPE WASH UNIT

The pipe wash unit consists of a cabin, in which the pipe is cleaned from contaminations and
salt deposits.
The cleaning water is supplied by the high-pressure unit, and is sprayed onto the pipe surface
in the cabin. The water falling from the pipe is collected on the bottom of the cabin and is
disposed of.
A wiper and an air knife are placed to remove superfluous water from the pipe surface.

3.13. CHROMATE APPLICATION UNIT
Figure 14: Chromate application unit.
The chromate application unit consists of a chemical mixing unit and a cabin in which the
pipe is treated.
The mixing unit is used to mix chromate with water. The correct ration of water and
chromate is determined by level electrodes in the mixing tank.
An agitator (mixer) mixes the water and chromate in the mixing tank. When mixing is ready,
a diaphragm pump pumps the contents of the mixing tank to the storage tank. The storage
tank is also equipped with an agitator, to keep the chromate mixture homogeneous. From the
storage tank, the chromate runs to the application cabin by gravity.
In the application cabin, the chromate is applied to the pipe by a rotating brush. The brush is
pneumatically pressed against the pipe. Spilled or overflown chromate is collected on the
bottom of the application cabin, and is pumped back to the storage tank.

3.14. FBE APPLICATION UNIT

The epoxy powder unit consists of an application cabin and an epoxy powder supply and
reclaim system (see Figure 15).
Epoxy powder is manually filled in the virgin powder hopper. A transport screw conveys the
epoxy powder from the virgin powder hopper towards the rotary sieve / fluid bed. A magnetic
separator is placed at the entrance of the rotary sieve, to extract steel particles from the epoxy
powder.
The rotary sieve separates waste parts and congealed powder lumps from the powder. The
fluid bed creates a mixture of air and epoxy powder, by blowing compressed air through a
porous plate on the bottom of the fluid bed. This air flows through the epoxy powder, thus
creating a mixture of air and floating epoxy powder particles, suited for electrostatic
spraying. The powder is transported towards the spray guns with the aid of compressed air.
The cabin is equipped with 28 spray guns. During spraying, the epoxy powder is statically
charged. An earth connection brush is placed just in front of the cabin to assure earthing of
the pipe. This creates a magnetic effect between the pipe and the powder and therefore the
pipe attracts the powder. During spraying, the epoxy powder melts onto the hot pipe.
Some epoxy powder will not be sprayed on the pipe (overspray) and is collected on the
bottom of the cabin. This powder is sucked back through the epoxy recovering tube to the
dust filter. The air is filtered by the dust filter and the recovered epoxy powder falls down to
the recovered powder hopper.
The amount of air sucked out of the cabin is controlled with the two cabin air flow regulating
valves mounted in the duct coming from the cabin.

Figure 15: FBE application unit.
The recovered epoxy powder in the recovered powder hopper is suited for reuse, and is
transported to the rotary sieve / fluid bed by a transport screw. The powder is led through a
rotary valve on top of the rotary sieve / fluid bed, which prevents air from flowing through
the transport screw.
Thus, during the spraying process, a mixture of virgin and recovered epoxy powder is used.
The virgin powder hopper and the fluid bed are connected with vacuum hoses to the dust
filter, to prevent powder leakages. The amount of vacuum is controlled by suction valves on
the dust filter.
A waste tank is connected to the recovered powder screw, to remove unusable recovered
powder from the recovered powder hopper.

3.15. ADHESIVE AND COATING LAYER EXTRUSION

After the epoxy layer is applied, an adhesive layer and a coating layer are extruded onto the
pipe. One extruder is used to produce the adhesive layer and one extruder is used to produce
the coating layer.
Figure 16: Side view coating area.
The adhesive and coating granules are transported to the extruders by vacuum hopper loaders.
At the entrance on top of the extruders, magnetic separators are placed to extract steel
particles from the granules.
Each extruder consists of a screw, which rotates in a cylinder. The extruder screws are driven
by direct current electric motors. The speed of the motor is reduced by a gearbox. The
adhesive extruder motor is connected to the gearbox with a coupling. The coating extruder
motors are connected to the gearbox with V-belts. The extruders pressurize and heat the
granules and press it out of the extruder flat head dies, forming a homogeneous adhesive and
coating film. A screen is placed between the extruder and the flat head die to extract any
foreign objects from the coating material. These screens are mounted in screen changers,
which allow for quick changing of a polluted screen.
In order to control the temperature of the extruders, the extruders are provided with a
heating/cooling system. The various zones of the extruder and the piping are heated
electrically. Water cooling is used for the entrance section (bushing zone) and air cooling is
used for the cylinder and the piping. To assure that the extruders, the adhesive and the coating
material are at operating temperature, the extruders heating/cooling system must be turned on
several hours before production starts.

3.16. PRESSURE ROLLER SYSTEM AND WELD SEAM COMPENSATION

The extruded adhesive and coating films are led to the pipe by rollers to guide and press the
film onto the pipe surface. These pressure rollers are pneumatically pressed against the pipe.
The adhesive pressure roller and the coating pressure roller are air cooled by blowing
compressed air onto the roller surface.
In order to assure the required coating thickness on the weld, extra coating material can
automatically be applied on the weld by momentarily accelerating the guiding roller. This
weld seam compensation functions as follows:
The peripheral velocity of the pipe is measured by a tacho mounted on the coating pressure
roller. This speed is used to control the servo motor driven guiding roller, which leads the
coating film to the pressure roller. When extra coating material is needed, the guiding roller is
accelerated. When the guiding roller accelerates, the coating film between the guiding roller
and the pipe is moved slightly faster to the pipe, creating a thicker and wider layer. To
determine the moment the guiding roller must be accelerated, a weld seam detection sensor is
placed against the pipe. This sensor gives a signal to the control system, and after an
adjustable time of delay, the guiding roller accelerates for a short time. This so called coating
time is also adjustable.
It is also possible to manually control the acceleration of the guiding roller.
NOTE: The weld seam compensation does not increase the total amount of extruded
material. It only distributes the amount of extruded material more efficiently
on the pipe.
The weld seam compensation functions with both longitudinally and spirally welded pipes,
but the results are optimal with longitudinally welded pipes.

3.17. QUENCH
The quench cools the pipe down to an acceptable temperature by spraying water on and in the
pipe. Water is pumped from the basin through the manifold to adjustable spray pipes. The
spray pipes are mounted on the ceiling and on the bottom of the entire quench length and
high capacity jet nozzles are placed at various points at the quench sides. In the first 2.5
metres, spray pipes are also mounted along the sidewalls of the quench. Water falling off the
pipe is collected in the basin. The sides of the quench are closed with curtains to keep the
water inside.
The quench water is pumped through a cooling tower to maintain an acceptable water
temperature.
The steam is extracted from the quench by three ventilators on the roof of the quench.
The cooling tower cools the water down by evaporation. A ventilator on the cooling tower
increases the cooling tower capacity.
3.18. HOLIDAY DETECTOR

The holiday detection station consists of a brush and a holiday detector, to check the coating
on porosities. The high voltage is applied to the pipe by a copper brush. The pipe runs on the
coating conveyor along this brush. When a holiday is detected, the area is marked with paint.
Two holiday detectors are provided: one low voltage unit to check FBE coating and one high
voltage unit to check 3-layer coating.
3.19. PIPE END CLEANING STATION

The pipe end cleaning station consists of two rotation units and two brush units.
3.19.1. Rotation units
The rotation units are mounted on motor driven carriages. Each rotation unit consists of a
wheel pair of which one wheel is driven by an electric motor, in order to rotate the pipe
during brushing.

3.19.2. Brush units
Each brush unit has two motor driven rotating brushes mounted on a carriage.
Figure 17: Brush unit.
The lower brush is mounted on a hinged frame directly onto the carriage. The upper brush is
mounted on a hinged guidance and can be moved with a spindle in forward and reverse
direction.
The carriages are moved towards the pipe ends after which the brushes are pneumatically
pressed against the rotating pipe. Both the lower brush and the upper brush rotate in axial
pipe direction. The lower brush is used for course brushing and removes most material. The
upper brush is used for final brushing and creates a smooth coating transition. During
brushing, both brushes are moved over the pipe in axial pipe direction towards the pipe end.
Brushed off coating is sucked away by the dust filter.
The position of the carriage (and thus the lower brush) in relation to the pipe end is
determined by the adjustable pipe end roller.
The position of the upper brush is manually adjusted during brushing with the joystick on the
control panel.

INDEX
abrasive ........................................................................................................................ 16, 23, 24
abrasive screw .......................................................................................................................... 23
abrasive valve........................................................................................................................... 23
adhesive.............................................................................................................................. 32, 33
agitator ..................................................................................................................................... 29
air ..................................................... 5, 14, 15, 16, 18, 20, 21, 23, 24, 26, 27, 28, 30, 31, 32, 33
air cooling ................................................................................................................................ 32
angle adjustment ................................................................................................................ 21, 26
blast wheel ............................................................................................................................... 23
blaster ................................................................................................... 10, 14, 15, 16, 19, 22, 23
blaster cabin ................................................................................................................. 14, 16, 23
blow-out station ............................................................................................... 10, 14, 15, 16, 24
brush ....................................................................................................................... 29, 30, 34, 35
brush unit ........................................................................................................................... 34, 35
brushes ..................................................................................................................................... 35
burner ................................................................................................................................. 20, 21
bushing zone ............................................................................................................................ 32
carriage............................................................................................................................... 24, 35
carriages ............................................................................................................................. 34, 35
centre adjustment ............................................................................................................... 22, 26
chemical mixing unit................................................................................................................ 29
chromate....................................................................................................................... 12, 27, 29
chromate application unit............................................................................................. 12, 27, 29
coating ................................................ 4, 6, 7, 8, 9, 12, 13, 14, 18, 19, 25, 26, 27, 32, 33, 34, 35
connecting rod .................................................................................................................... 21, 26
control cabinet.......................................................................................................................... 20
control panel....................................................................................................................... 21, 35
conveyor ............................................................................. 10, 12, 14, 19, 21, 22, 25, 26, 27, 34
cooling.......................................................................................................................... 12, 32, 34
cooling tower ..................................................................................................................... 12, 34
counter flow fan ....................................................................................................................... 27
diabolo conveyor ................................................................................................................ 10, 25
diaphragm pump ...................................................................................................................... 29
diaphragm valve ....................................................................................................................... 14
dust filter ...................................................................... 10, 14, 15, 16, 17, 18, 23, 24, 30, 31, 35
elevator..................................................................................................................................... 23
epoxy powder ............................................................................................... 5, 14, 15, 17, 30, 31
epoxy powder unit.................................................................................................... 5, 15, 17, 30
extruder .................................................................................................................................... 32
extruders................................................................................................................................... 32
FBE unit ................................................................................................................................... 17
filter bag ....................................................................................................................... 14, 15, 17
filter cartridge......................................................................................................... 14, 15, 16, 18
flat head die .............................................................................................................................. 32

fluid bed ....................................................................................................................... 17, 30, 31

gas .......................................................................................................... 5, 10, 12, 19, 20, 21, 26
gearbox ..................................................................................................................................... 32
grease ......................................................................................................................................... 4
guiding roller............................................................................................................................ 33
heater ............................................................................................................................ 19, 21, 26
heaters ................................................................................................................................ 19, 27
heating/cooling system............................................................................................................. 32
holiday detection station .................................................................................................... 12, 34
holiday detector........................................................................................................................ 34
hopper loader ........................................................................................................................... 32
inspection station ................................................................................................... 10, 12, 14, 25
kick-out .................................................................................................................................... 14
lower brush............................................................................................................................... 35
lower-in .................................................................................................................................... 14
magnetic separator ............................................................................................................. 30, 32
main heater ............................................................................................................................... 12
mixer ........................................................................................................................................ 29
mixing tank .............................................................................................................................. 29
next pipe ................................................................................................................................... 27
nozzles...................................................................................................................................... 34
pipe diameter.................................................................................................................. 4, 22, 26
pipe end cleaning station.................................................................................. 12, 14, 15, 18, 34
pipe end cleaning unit .............................................................................................................. 14
pipe length .............................................................................................................................. 4, 7
pipe racks ..................................................................................................................... 10, 12, 14
pipe wash unit .................................................................................................................... 12, 28
preheater............................................................................................................................. 10, 22
pressure roller........................................................................................................................... 33
quench .................................................................................................................... 12, 26, 27, 34
rotary sieve ......................................................................................................................... 30, 31
rotation unit ............................................................................................................ 14, 24, 25, 34
screen ....................................................................................................................................... 32
screen changer.......................................................................................................................... 32
sensor ....................................................................................................................................... 33
sieve ....................................................................................................................... 16, 23, 30, 31
sieve grate ................................................................................................................................ 23
spray pipes ............................................................................................................................... 34
stopper ...................................................................................................................................... 14
storage tank .............................................................................................................................. 29
timer ......................................................................................................................................... 14
transport screw ............................................................................................................. 17, 30, 31
upper brush............................................................................................................................... 35
V-belt ....................................................................................................................................... 32
ventilator .................................................................................................... 14, 16, 17, 18, 21, 34
water..................................................................................................................... 4, 5, 28, 29, 34

weld seam......................................................................................................................... 4, 9, 33
weld seam compensation ......................................................................................................... 33
weld seam detection sensor...................................................................................................... 33
wheel support ..................................................................................................................... 21, 26

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CHAPTER 1

2. TECHNICAL SPECIFICATION .............................................................................................2

CHAPTER 1. TECHNICAL DESCRIPTION

EXTERNAL PIPE BLASTING AND COATING PLANT

Pipe diameter range 123/4" to 48" (324 mm to 1219 mm).

Manufactured by: Selmers B.V.

Designed for: Servicios Condumex, S.A. De C.V.

Year of manufacture: 2007

Part 1 - book 1 Chapter 1 - Page 1

ATTENTION: The equipment is not designed or intended for any

Part 1 - book 1 Chapter 1 - Page 2

2.1. STEEL PIPE DIMENSIONS

Applied diameter range:

Pipe wall thickness:

2.2. TYPES OF PIPES TO BE HANDLED

Pipes shall conform to API Specification 5L.

Part 1 - book 1 Chapter 1 - Page 3

2.3. PIPE TOLERANCES

For wall thickness up to 8 mm: max. 2.5 mm

2.4. PIPE SURFACE CONDITIONS

Part 1 - book 1 Chapter 1 - Page 4

2.5. POWER AND UTILITIES

Required quality for epoxy powder unit:

Reverse osmosis water:

Part 1 - book 1 Chapter 1 - Page 5

2.6. OPERATING CONDITIONS

Climatological conditions inside building:

Climatological conditions outside building:

2.7. APPLICATION METHOD

External single layer FBE-coating:

Part 1 - book 1 Chapter 1 - Page 6

External 3-layer PE-coating:

- Adhesive layer: nominal 250 microns

- Total coating layer thickness according to DIN 30670 (standard coating):

It is possible to produce a reinforced coating of max. 3.7 mm at reduced production capacity.

2.8. PRODUCTION CAPACITY

Part 1 - book 1 Chapter 1 - Page 7

External blasting and single layer FBE coating:

External blasting and 3-layer HDPE coating:

Part 1 - book 1 Chapter 1 - Page 8

The capacity rates are based on the following conditions:

Part 1 - book 1 Chapter 1 - Page 9

1 Two inbound pipe racks

The numbers refer to Figure 1:

Part 1 - book 1 Chapter 1 - Page 10

Figure 1: External blasting section

Part 1 - book 1 Chapter 1 - Page 11

The external coating section consists of the following parts:

The numbers refer to Figure 2:

Part 1 - book 1 Chapter 1 - Page 12

Figure 2: External coating section.

Part 1 - book 1 Chapter 1 - Page 13

3.1. PIPE RACKS

3.2. STOPPER, LOWER-IN AND KICK-OUT

3.3. INSPECTION STATIONS

3.4. DUST FILTERS

Part 1 - book 1 Chapter 1 - Page 14

3.4.1. External blaster dust filter

Figure 3: Working principle external blaster dust filter.

Part 1 - book 1 Chapter 1 - Page 15

3.4.2. Blow-out station dust filter

Figure 4: Working principle blow-out station dust filter.

Part 1 - book 1 Chapter 1 - Page 16