13-Jan-2016 Düsseldorf / Germany
Henkel and Xervon demonstrate the Loctite Repair System in real life
Loctite, the solution provider for adhesives, sealants and protective coatings within the Henkel Group, and the German maintenance service provider Xervon have repaired pipelines in the home factory at Henkel’s headquarters in Düsseldorf (Germany) using the new Loctite Composite Repair System. The innovative system increases pipe lifetime by up to 20 years. Another advantage is that pipelines can be repaired without interrupting operations, thus avoiding the often high costs associated with unplanned shutdowns.
The Henkel plant in Düsseldorf is criss-crossed by 18 kilometers of piping bridges and 300 kilometers of pipelines. Maintaining these steel pipelines and repairing any leaks quickly, safely and sustainably is a top priority for the operator. The Loctite Composite Repair System restores even heavily corroded pipes to an as-new condition and can extend their lifetime by up to 20 years.
“20 years is the target timescale – also for competitor products. But we are confident that the Loctite Composite Repair System can last far beyond that period,” says Carsten Sperlich, who heads the Technical Infrastructure department at the Düsseldorf site and is thus responsible for ensuring the pipe bridges are in perfect working order. “The new system is very interesting for us because it means that we can repair corroded pipelines without interrupting operations, which eliminates the costs that would be generated by unplanned shutdowns of production facilities.”
Repair rather than replace
For the pilot project, a ten-meter long section of piping was repaired with the Loctite composite system. Traditionally, the user would have to replace that pipe section. “With the innovative repair system from Henkel, the piping is as good as new,” says Bernd Hammer, Global Market Development Manager for Oil & Gas and Refineries at Adhesive Technologies. And this is how it works: The surface of the defective pipe section is cleaned by sandblasting. Next, Loctite SF 7515 is applied as a temporary corrosion inhibitor. The backbone of the repair system is laid by wrapping the pipe with several layers of high-strength glass-carbon fiber tape Loctite PC 5085 which has been pre-impregnated with the two-part epoxy resin Loctite PC 7210. Finally, several layers of topcoat Loctite PC 7255 are applied as corrosion protection. The Loctite Composite Repair System has been certified by DNV GL in accordance with the global quality standard ISO 24817. The method has also been approved by Lloyds Register, in conformity with the ASME PCC-2 standard, and by TÜV Rheinland.
Penetrating markets together
The company Xervon applied the Loctite Composite Repair system to the pipelines in the Henkel plant. This enterprise, headquartered in Cologne (Germany) is one of a select number of service providers that Henkel works with in its “Henkel Certified Applicator” network. Before beginning the project, Xervon employees received extensive training in comprehensive seminars. The Loctite Composite Repair System is being used worldwide in refineries, petrochemical plants, power plants and water treatment systems. Since existing production plants are reaching an age when they require a general overhaul, the interest in the repair system is correspondingly high. “That’s why it was so important to apply the system in our own Henkel plant. We can present this in-situ reference project to our customers and also monitor it over the long term, allowing everyone to see for themselves the level of quality this repair provides,” says Bernd Hammer from Henkel.