Field Application Process
CLEANING PROCESS
Assuming the pipe line is ready meaning free of any unwanted materials or object inside, the cleaning machine can go ahead without the inspection machine to pre-video the pipeline. It can start doing the cleaning process on each girth weld (standard 15 G.W. per string). After Cleaning the whole string and verified that it is set to go for coating application it will move to the next pipe string to start cleaning again.
INTERNAL COATING PROCESS
On this stage the girth weld now is clean and ready for coating. In this process the girth weld will be subject to heating by means of induction heating using induction coils prior to coating application. Post cure heating will be applied after internal coating is done which is also the applied temperature for external coating.
INSPECTION PROCESS
This is the process in which the applied internal coating is subject for holiday test, mils measurement and at the same time checking the physical appearance of the applied coating if there is any presence of bubbles, orange peel or any abnormalities on the surface of the applied coating.
EXTERNAL COATING PROCESS
On this stage right after the internal coating process is done and post curing heating (application temperature of external coating also) has been applied for curing the internal coating, the external coating process could begin and start the application of external coating right away.
INTERNAL EQUIPMENT
CLEANING MODULE
- 260mm Ø cleaning head for powerful centrifugal force
- 3000 RPM motor
- Linear actuators with sensors for Cleaning Head adjustable linear movement
- Transmission system for faster cleaning head rotation
- Ramp circuit for gradual start-up
INTERNAL COATING PROCESS
- Faster application with a 4-spray nozzle coating head
- Gear motor for coating head rotation
- Air compressor for pneumatic valve & seal air supply
- High resolution mini camera for line travel & girth weld spotting
- Video transmitter
- Powder block with adjustable flow gate for precise flow rates.
- Blower block with air gates for precise airflow control
INSPECTION PROCESS
- Holiday detector - 10Kv
- DFT Gauge
- High resolution mini camera
- Motor step drive for stepper motors
- 2 x stepper motors
- Air compressor for pneumatic valve
- Solenoid valve
- Pressure switch
- Change-over valve for grit suction & discharge (cleaning) operation
- Compressor drive motor
- Vacuum blower for grit suction
- Air compressor for change-over valve air supply
- High resolution mini camera for pre-coating inspection
- Video transmitter
- Stepper motor for camera angle (360°)
- Adjustable polycarbonate vacuum head
EXTERNAL COATING PROCESS
EXTERNAL EQUIPMENT
EXTERNAL APPLICATOR
- AC powered geared motor for 360° rotation
- Latching mechanism for quick locking and releasing from the pipe
- Control box unit for applicator movement control
- Minimum of two (2) Coating Head (varies as the pipe diameter size gets bigger)
INDUCTION HEATING COIL
- Latching mechanism for quick locking and releasing from the pipe
- Fiber wood for electrical connection terminal
- Welding cable for wrap around heating coil
- Customize coil connector for current flow continuity
- High temperature wheel for easy line travel transferring from joint to joint
FLUID BED
- Custom-built external powder block with adjustable fow gate for powder control
- Air pressure regulator for air flow control for powder blowing and powder fluidization
- Air cylinder tank for air supply reservoir
- Electronic air valve for automatic on/off of air supply for both powder-delivery for coating process and powder fluidization.
- Control box for fluid bed operation.
(WCS) WIRELESS CONTROL SYSTEM AND HARDWARE
- Wireless Hand-Held Device Unit.
- Provide video and command control to wireless command tower.
- Wireless mini command tower - include router, video network unit, RS232 unit, wireless video and data transmitter receiver
- Process control unit.
- Encoder command and distance control unit
- Speed control