Neptune Research, Inc. - Pipe Repair and Pipe Reinforcement Technology

QA/QC Material Traceability:

ISO (see ISO certificate)

Manufacturer’s Lot Number: located on foil pouch, above seal. Lot # example:
1104256

Procedures to be taken in handling and storage:

For ideal shelf life, store in a cool, shaded area at an ambient temperature of 72°F (23°C). Do not expose materials to temperatures above 110°F (44°C) or below 40°F (5°C).

Syntho-Glass® UV is packaged within a hermetically sealed foil pouch to protect the Syntho-Glass® UV outer composite wrap from atmospheric moisture. Because the Syntho-Glass® UV outer composite wrap cures when exposed to the application of water or air humidity, care must be taken in handling the sealed bags to prevent puncturing or scuffing. If the protective foil pouch is punctured the Syntho-Glass® UV outer composite wrap will be exposed to atmospheric moisture which will cause the Syntho-Glass® UV outer composite wrap to cure within the foil bag.

Shelf Life:

NRI provides a 6 month shelf-life if Syntho-Glass® UV is stored in a cool dry place and the protective foil pouch is free from puncture damage.

INSTALLATION GUIDE

1. Scope
   1. This Installation Guide may be used for the application of the Syntho-Glass® UV System for a UV stable outer wrap and mechanical barrier of any of the following surfaces: carbon, stainless and alloy steel pipe, fittings, flanges, structural supports, other corrosion prevention coatings (including petrolatum tape, epoxies, shrink sleeves, or any cold applied tapes) for above ground, below ground, sub-sea and splash zone service.
   2. Pipe and pipeline repairs for wall loss, holes, cracks, leaks or fissures fall outside of the scope of this Installation Guide.
   3. The installer shall follow the general guidelines provided by this Installation Guide to ensure that the implementation of the Syntho-Glass® UV System is comprehensive and correct for the specified work.
   4. The installer shall also follow any written procedures providing further details appropriate for specific types of applications, to ensure that the implementation of the Syntho-Glass® UV System is comprehensive and correct for the specified work.
2. General Requirements
   1. The Engineer shall comply with all written recommendations of the Manufacturer regarding the application of the Syntho-Glass® UV System, as well as regarding the completion of written reports on each repair job.
   2. To obtain the material specifications and installation manual, contact: NRI, 1346 S Killian Drive, Lake Park, FL 33403, 561-683-6992 (phone), 561-683-8366 (fax), customerservice@neptuneresearch.com (email).
3. Materials
   1. Syntho-Steel™ Epoxy Putty (Part No. SS02 or SS07)
      1. The Syntho-Steel™ Epoxy Putty is a high compressive strength (12,000 PSI) two-part, premeasured, steel filled epoxy stick.
         1. After cure, the Syntho-Steel™ Epoxy Putty will provide benefits which may include sealing, load transfer, and the creation of a smooth transition between areas of different geometries and the Syntho-Glass® UV outer wrap.
         2. Syntho-Steel™ Epoxy Putty is designed for underwater & above water sealing applications. The putty should be applied firmly to the area to ensure no voids or air is trapped between the filled area & the epoxy putty. One the putty is applied to the substrate, make sure the edges of the putty are feathered out or sanded to create a uniform contoured surface area
      2. The Physical Specification values shall meet the values given on the Data Sheet for Syntho-Steel™.
   2. Syntho-SubSea™ LV Epoxy (Item No. SUBLV_04OZ, SUBLV_08OZ, SUBLV_16OZ, SUBLV, SUBLVG, SUBLV10G, SUBLV.4) Storage cans or .4 gallon cartridges (Item # SUBLV.4) which requires a pneumatic applicator gun (Item # PNEUMATIC_GUN) and static mixing nozzle (Item # SUBLVNOZ).
      1. Syntho-SubSea™LV Epoxy is a non-hazardous epoxy formula.
      2. Syntho-SubSea™LV Epoxy is comprised of a KEVLAR-reinforced two-part resin (Liquid Epoxy Resin and Amine-based Curing Agent).
      3. After cure, the Syntho-SubSea™LV Epoxy will provide benefits which may include sealing, corrosion protection, load transfer, adhesion between substrates, and the creation of a smooth transition between the damaged area and the Syntho-Glass® UV.
      4. Syntho-SubSea™LV Epoxy is designed for underwater & above water sealing applications. It should be applied at a range of 30-60 mil (0.762-1.524 mm) thickness.
      5. The Physical Specification
   3. Syntho-Glass® UV (Part No. UVW520, 930, 415, 430, 450, 830, 840, 850)
      1. As packaged, Syntho-Glass® UV is comprised of an asymmetric biaxial plain weave fiberglass tape that is impregnated by an uncured (liquid) polyurethane resin.
      2. The resin component of Syntho-Glass® UV is activated by fresh or salt water and hardens as it cures, resulting in a thermoset composite that is UV stable and will not degrade or yellow under intense UV exposure.
      3. The hardening of the resin component produces a hard, fiberglass-reinforced composite sleeve, resistant to attack by petroleum products and many other chemicals.
      4. The Physical Specification values shall meet the values given on the Data Sheet for Syntho-Glass® UV.
4. General Surface Preparation Requirements
   1. Remove pipe coating, loose rust, paint and other foreign matter.
   2. Prepare surface in accordance with Sa 2.5 or NACE 2, near white Metal. Or as directed for the corrosion coating being applied.
   3. If applying Syntho-Glass® UV onto an existing corrosion coating system, it is recommended to scuff the outer surface of the coating system (if applicable) to insure good adhesion to the existing coating.
5. Application of Syntho-Steel™ as Filler Material (if needed)
   1. Syntho-Steel™ is supplied in a pre-proportioned stick with the proper amount of resin and hardener. Working time is only 2 minutes. Mix only enough epoxy putty that you can install in 2 minutes.
   2. Remove all plastic wrap and foil dots from end of epoxy stick.
   3. Complete and thorough mixing of the two parts is required in order to obtain the correct physical properties; mix and blend by twisting and kneading the putty so it is uniform in color with no streaks.
   4. Apply putty to clean, prepared surface by using hands, spatula, or putty knife, working the material into all indentations to assure that no air bubbles remain.
   5. Fill all pits, dents and other anomalies with putty to match the contour of the outside diameter of the pipe. Sand to the contour of the pipe.
6. Application of Syntho-SubSea™ LV (if needed)
   1. Syntho-SubSea™LV is supplied in two precisely proportioned parts: Part A, Liquid Epoxy Resin; and Part B, Curing Agent (also known as “Hardener”).
   2. The mix ratio of this epoxy system is 1:1 (equal parts resin to hardener).
   3. Add all 100% of the Curing Agent (Part B) into the container of Liquid Epoxy Resin (Part A). It is essential for the installer to add all of Part B into the container of Part A in order to achieve proper curing.
   4. Complete and thorough mixing of the two parts is required in order to obtain the correct curing properties; and can be achieved by stirring the two parts together until a smooth, uniform, streak-free consistency is reached. A jiffy mixer and handheld drill can be used to mix 100% of the A & B in a clean bucket.
   5. Apply mixture to clean, prepared surface by using a spatula, trowel or putty knife, working the material into all indentations to assure that no air bubbles remain.
   6. Feather the edges of the application to ensure a water-tight seal.
   7. Apply Syntho-SubSea™LV around entire circumference of pipe. NOTE: inspect the Syntho-SubSea™LV coverage to ensure proper mil thickness of 30mil – 60mil using a wet thin film mil gauge. Make sure 100% of the pipe surface is coated to ensure no holidays or bare steel is exposed.
   8. A 30mil – 60mil thickness is recommended for the Syntho-SubSea™LV primary layer.
7. Application of Syntho-Glass® UV
   1. Do not open the bag containing Syntho-Glass® UV until you are ready to use it.
   2. In hot or humid location, water shall be sprayed on each layer of Syntho-Glass® UV while it is being applied (instead of immersing the full roll in water before application), in order to slow down the curing and thus provide the installer sufficient working time.
   3. In Cold Weather applications, the temperature of the repair area must be brought up to 5oC (40oF) prior to the application of Syntho-Glass® UV since its resin component will not begin to cure at lower temperatures.
   4. The tape shall be spirally wrapped around the pipe, flange, fittings, etc with a 50% overlap.
      1. Each completed wrap over the repair area shall have the specified number of layers of Syntho-Glass® UV when completed. Note: Either a 4 or 8 layer system is recommended depending on the environment and expected wear.
      2. Hold the end of the tape firmly to the surface of the pipe at the starting point. The starting point shall be approximately six inches beyond the borders of the corrosion coating area.
      3. Unroll the tape, keeping it as close to the surface of the pipe as possible. Do not use a long lead of tape. The roll of tape shall always be in an upright position, with the tape being applied from the lower edge of the roll to maintain proper tension.
      4. Apply sufficient tension by pulling on the roll of tape as the layers are being applied.
      5. The tape may be applied from right to left (R-T-L) or from left to right (L-T-R). At the end of the first wrap, reverse the direction of the wrap and continue to apply the Syntho-Glass® UV. Do not reverse the direction of the application without completing an entire wrap along the length of the repair area.
   5. The Syntho-Glass® UV application shall extend, with the same number of layers as being applied over the wrap area itself, into an “overwrap” region beyond the coated region in the axial direction on each side of the coated region.
   6. The Syntho-Glass® UV application shall be tapered at both ends of the repair area, beyond the overwrap region.
   7. After the application of Syntho-Glass® UV, the entire area shall be manually molded and squeezed into the cloth in the direction of the wrap. This procedure shall be repeated every four layers (two wraps).
   8. The completed Syntho-Glass® UV application shall be overwrapped by two to four layers of compression tape & perforated using the perforator tool. The compression tape may be removed when Syntho-Glass® UV has reached its initial cure time.
   9. The Syntho-Glass® UV installation shall be ready for service when the resin has cured sufficiently to provide adhesion between layers and has reached a hardness of 74 Shore D.
   10. For Vertical Installations such as Offshore Risers or Jacket Legs, Syntho-Glass® UV application shall begin at the bottom of the repair area and proceed upwards.
   11. For Sub-Sea and Splash Zone Installations, the last (outer) wrap shall be tied down or overwrapped in a manner that will ensure that the currents or wave action will not affect the adhesion of the last layer of fiberglass tape before the resin has reached its initial cure (the compression film will suffice for this).
       1. For Sub-Sea Installations, open the bag of Syntho-Glass® UV underwater, at the repair site, after all cleaning has been completed, and only when ready to apply directly to the substrate.
       2. For higher impact resistance, you may apply additional layers of Syntho-Glass® UV.
   12. For Cold Weather Installations, follow procedures above. However, as an additional step, after applying the final outer wrap of a plastic film, apply a heating pad over the entire repaired area since Syntho-Glass® UV will not cure by itself at temperatures under 5°C (40°F).
   13. For Hot Weather Installations, follow procedures above. However, use ice water in the sprayer if possible, to slow down the curing and thus allow the installer sufficient working time. Furthermore, store unopened bags of Syntho-Glass® UV in a separate container in an ice chest if possible to keep the rolls cool.
   14. The installer shall follow the recommendations provided by the manufacturer with regard to the minimum required number of layers of Syntho-Glass® UV for specific types of overwrap projects.