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What is the Method Statement for Bituseal Enamel Application?
A Method Statement for Bituseal Enamel Application would typically outline the step-by-step procedure for applying Bituseal enamel on a surface. Bituseal enamel is a type of bituminous coating used for waterproofing and corrosion protection.
Bituseal Enamel Application Method Statement
Based on a carefully chosen bitumen that has been treated with high performance engineering polymers, Bituseal Enamel is used.
The product’s flexibility, adhesion, and durability are just a few of the features that this polymer alteration will ensure.
Depending on the various needs for corrosion protection materials for pipelines, Bituseal Enamel is supplied in a variety of types and grades.
The extruder head, which is capable of delivering a consistent and uniform mass of Bituseal Enamel, is the most important aspect in the application process.
Depending on the outer wrap width and coating speed, the extrusion head’s slot’s length and width can be changed.
By entering the following parameters into the computer, the process variables can be precisely monitored and controlled at any rate:
Pipe diameter Required coating thickness Wrap width Pipe forward/rotational speed
Based on the specified process factors, the precise material requirements are calculated. The extrusion technology for Bituseal is temperature independent, in contrast to standard flood coated enamel systems where the thickness is primarily controlled by flow, pipe speed, and temperature.
One of the main sources of uncertainty in the coating process has been eliminated because enamel temperature is no longer a variable component, leading to increased process control and quality assurance.
Diagram of the Bituseal process flow
Principal Components
- Application Head for Bituseal Enamel
- Heating Unit
- PLC Control Unit
- Melting Tank
- Storage Tank
- Filling Pump for Storage Tank
- Supply Pump
Melting Tank
If the Bituseal Enamel is supplied in 50 kg solid blocks, a melting tank is necessary.
Dependent on Bituseal Enamel consumption rate, tank size.
Storage Tank
The Bituseal Enamel must be heated to the precise temperature and maintained within a temperature differential of 1 oC in the tank since the application temperature is often between 210 and 215 oC.
Tank size is determined by Bituseal Enamel’s production rate.
Pump for filling storage tank: When necessary, the pump moves Bituseal from the melting tank to the storage tank.
Supply Pump
Continuously delivering Bituseal Enamel into circulation pipe lines is the pump for the Bituseal Enamel application and the weld seam application.
When the coating process is carried out, the pump rotations will be regulated to give the precise amount of Bituseal Enamel required for the applications, and the material will be lead through the application head to the applications.
Bituseal Enamel will flow through the circulation lines and return to the supply tank when the process is turned off.
Heads of Applications
The extruder head has integrated application heads for coating pipe and weld seams. The opening width of the weld seaming extrusion can be adjusted from 50 to 100 mm. The opening width of the pipe application extruder is approximately 200 to 750 mm.
Weld seam first, then pipe application, is how the two processes work. Three features are already present in the two extruder heads:
- Opening for application: By activating, the head’s orifice is widened and Bituseal Enamel is ejected as a “carpet” from the head.
- Cleaning: By activating the cleaning function, the extrusion hole of the head can be momentarily wider opened in case a particle in the Bituseal Enamel should give a split in the extruded Bituseal carpet.
- A valve that closes the Bituseal Enamel return line to the supply tank closes it when the coating process is running. The Bituseal Enamel runs through the head and back into the supply tank when the process is stopped.
Three electric/pneumatic valves inside each head control all functions at a constant rate.
The Primary Purpose of Weld Seam Coating
The purpose of the weld seaming is to ensure that the Bituseal coating above the weld seams has the minimal thickness required. The pipes may be spirally or longitudinally welded.
The pipe must be precisely positioned 5 to 7 cm vertically under the application head when the weld seam application is carried out. The Bituseal starts to flow from the head by activating the application start button, and the pipe starts to move while maintaining its weld seam in the proper alignment with the application head.
Bituseal Enamel flow and pipe movement are automatically estimated and regulated by the electrical control.
An employee is required to oversee the weld seaming process and handle any small adjustments that arise.
Principal Purpose of Pipe Coating
Continuous pipe coating is done at the plant.
The following parameters are set via the electrical control panel:
- Wrap thickness
- Wrap width
- Wrap overlay
- Wrap speed
- Pipe diameter
To give the precise pitch per pipe revolution on the conveyor, the angle of the support rollers for the pipes must be manually adjusted.
The width of the wrap less the wrap’s overlay is the proper pitch.
In order to give the desired coating, the flow of Bituseal Enamel will be automatically regulated by the electric control in accordance with the pipe rotation speed.
In the coating pan, the application head must be positioned 8 to 12 cm above the pipe. The Bituseal Enamel will flow from the head to the pipe by activating the start button.
To ensure that splits do not occur in the Bituseal, the flow must be manually examined regularly.
The clean head button needs to be pressed right away in case there is a split in the Bituseal flow.
Heating System
The machine manages and feeds heating oil to pipes and tanks. Oil is being heated in an oil burner to a preset temperature (maximum 270°C).
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