Our Products At Work in the Field


FormaShield® System: External & Internal Corrosion


Veracruz, Mexico
February 11, 2018

Project Overview
A damaged flare line was experiencing external and internal corrosion defects, so required a 10-foot FormaShield® system repair. The line has a 36” OD, with a 0.375” wall thickness and a pipe grade of API 30,000. The MAOP is 150 PSI and the operating pressure is 14 PSI.

Repair Solution
A design package was created in accordance to ASME PCC-2 standards, and it required four layers of FormaShield over a 10-foot repair zone. The pipe was media-blasted to near-white metal using mechanical hand tools and cleaned with acetone to remove any oil residue. EP420 filler paste was used to create a smooth transition on weld seams and the general corrosion areas. When the EP420 had cured, PPR-adhesive primer was applied to the entire repair zone to prevent any moisture ingress. Four layers of FormaShield were applied as the structural reinforcement using the “layer over layer with an offset” method.

The final repair thickness was 0.132”. Peel ply was applied as the final step to compact the repair while it cured and to avoid any contaminants. The repair was left to cure for two hours, the peel ply was removed and a final coating was applied for corrosion and UV protection over the entire repair. 

Results
The installation was a success; the pipeline was never taken out of service, which allowed the customer to operate safely and continue with production. Installation was completed within five hours, including the two hours of set time. Finally, a hardness test was conducted with a Shore D value of 85. 

FormaShield_External and Internal Corrosion_Veracruz_LayeringFormaShield_External and Internal Corrosion_Veracruz_Compaction Peel PlyFormaShield_External and Internal Corrosion_Veracruz_Epoxy PrimerFormaShield_External and Internal Corrosion_Veracruz_After