Orbis Oxifree (TM198) Corrosion Coating

Completed

Fossil Fuels: Oil Gas and Coal(Oil and Gas, Refining, transport and storage of oil and gas)

Applied Research and Development

PHYSICAL SCIENCES AND MATHEMATICS (Metallurgy and Materials)
ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering)

Not Cross-cutting

Project Contact
SGN

Network Innovation Allowance

Ofgem

01 June 2014

01 May 2016

ENA months

£24,482

Energy

South East

Network Innovation Allowance

Project Contact, SGN

Project Contact, National Grid Gas Transmission
Project Contact, Northern Gas Networks
Project Contact, Wales and West Utilities

Orbis Oxifree Corrosion Coating (or Oxifree) is a new (to the GB gas market) and environmentally friendly applied polymeric resin coating/encapsulation system designed to prevent corrosion. It primarily targets pipe flanges, valves and bolts but also acts as a barrier to stop ingress of dust and moisture into a wide range of assets. Prior to application, the product is heated to a temperature of 170 degrees C in a purpose built machine and is then applied, via a heated hose and gun. The material is pumped at low pressure and forms an encapsulation which is around 4mm thick and does not adhere to the substrate. When applied, the product secretes oil which forms a barrier between the substrate and the polymeric resin to prevent air, moisture and contaminants from penetrating the coating/substrate interface. It also has an inhibitor quality which acts to reverse any established corrosion. The coating can be easily removed from the asset and melted down and reused, therefore this is a zero waste product both during and after the application process. There are a range of application machines which can be used and these include a small machine for ease of transport and working in confined spaces and restricted access work areas (i.e. rope access). There are also larger machines for greater material capacity holding an ATEX approved for us in potentially explosive/fire risk zones. Removing the encapsulation has been demonstrated to be very easy therefore allowing regular removal, inspection and re-application. This further supports the cost savings and environmentally friendly aspects of the product. The scope of the project is to validate the products suitability for use on GB gas networks. Work should include application of the method to a number of differing sites both above and below ground. This will allow the team to determine the potential success of the product in differing environmental conditions. Field trials should be conducted across the networks at a number of locations in order to highlight any areas or situations in which this product should not be used (i.e. engineering, social or geographic regions which may present challenging circumstances). Further, it might be included in the scope of this project to conduct regular checkbacks on assets treated using this product to determine any changes to asset life expectancy. The project should finally be used to determine in particular, which assets and equipment are appropriate for use with this product (and any that are not suitable). A work procedure should be produced and tested to ensure that a suitable protocol is in place for the product to be used safely and efficiently. A formal report should be produced and submitted to record all learning generated from the project to be shared with all appropriate parties. The objectives are to: Establish to what degree the validation testing for the offshore environment aligns with the validation requirements of the GB gas distribution environment, and to identify any testing gaps that may exist. Perform any offline material/application testing as identified in the above objective to give confidence that the Oxifree coating presents no risks if used on GB gas distribution assets. Trial the application of the Oxifree coating on a variety of networks assets to enable the following aspects to be assessed and determine: Costs for the application of the system for various asset types against existing costs of repair. Practicalitiesof using the coating system in a GB gas distribution network and the challenges of the varying environments. The performance of the technology over a six month period as compared to similar assets that have not received protective treatment.

The scope of the project is to validate the products suitability for use on GB gas networks. Work should include application of the method to a number of differing sites both above and below ground. This will allow the team to determine the potential success of the product in differing environmental conditions. Field trials should be conducted across the networks at a number of locations in order to highlight any areas or situations in which this product should not be used (i.e. engineering, social or geographic regions which may present challenging circumstances). Further, it might be included in the scope of this project to conduct regular checkbacks on assets treated using this product to determine any changes to asset life expectancy. The project should finally be used to determine in particular, which assets and equipment are appropriate for use with this product (and any that are not suitable). A work procedure should be produced and tested to ensure that a suitable protocol is in place for the product to be used safely and efficiently. A formal report should be produced and submitted to record all learning generated from the project to be shared with all appropriate parties.

18/10/23