Jindal Tubular USA Coating Facility
Jindal Tubular USA coating facility is an industry leader for FBE, ARO and internal Diameter Coatings. FBE and AROE and ARO are the primary outside diameter coatings used in North America to protect pipelines from corrosion. The Jindal Tubular USA coating facility is also capable of applying internal coatings ranging in uses from the mainline gas transmission to the water/wastewater industries. Jindal Tubular USA adheres to the highest technical and professional standards to provide our customers with the highest degree of quality possible for any coating project.
OD, FBE and ARO Electrostatic Applied Coatings
Surface Preparation: Begins by sending the pipe through and electric induction coil furnace to remove all surface moisture before blasting operations. The pipe then travels through a twin shot blast cleaning system. The first blasting machine consists of steel shot to initially clean the pipe surface. The second blasting machine consists mainly of steel grit which continues the cleaning process but also applies a desired profile (anchor pattern) that allows for optimum coating adherence.
Visual Inspection After Blast: After blast surface preparation the pipe is then visually inspected for any surface defects in the pipe material and repaired before moving forward into the coating application process. The inside diameter of the pipe is also cleaned with a blower/vacuum system at this stage to prevent any foreign material from traveling into the coating application process.
Acid Wash: The pipe is transferred to the acid wash/rinse/drying. This process consists of the pipe being heated to a desired temperature, processed through the acid wash application equipment (phosphoric acid), rinsed with ultra pure high pressure RO/EDI water then the pipe surfaces dried before leaving for the coating application process.
Coating Process: The pipe is transferred from the acid wash cleaning system to twin electric induction coil furnaces to elevate and maintain the pipe at the desired coating temperature. The pipe is temperature maintained and verified through electronic controls and well as periodically verified through manual temperature testing methods. The pipe then enters a FBE (fusion bond epoxy) application booth where the FBE coating applied through state of the art 24 gun electrostatic application equipment. Upon leaving the FBE coating booth the pipe then enters the ARO (Abrasion Resistant Overlay) coating application booth. This is an identical 24 gun state of the art electrostatic application system that is used in the FBE application process. The two systems are operated independently of each other but can be operated in tandem to allow for an outstanding “Dual Layer” application system. The pipe then leaves the coating application area and enters the quench (cool down” system to reduce the pipe temperature from desired application levels to the desired test levels.
Coating Application Inspection Process: The pipe is transferred onto the Coating Inspection Platform. During this process the pipe surface is visually inspected for any coating surface defects, the body and the weld seam of the pipe are checked through our “holiday detection” process, test pipe temperature is verified, coating thickness is verified and any minor surface repairs are made at this station. The recorded test information is then entered into our “customer specific” pipe tracking system and all pipes tracking information is verified before moving forward in the process.
At this point in the process the pipe is transferred off of the inspection platform and transportation separator rings are applied and moved out for shipment or if customer specified the pipe will be moved forward into the ID (Internal Diameter) Coating Process.
OD, FBE and ARO electrostatic applied coatings:
The Pipe is processed through an electric induction coil furnace to remove moisture from the ID pipe surface.
At this point the pipe is introduced into a state of the art fully automated ID coating System. The Pipe Transfer system moves a pipe into the ID blast station. The pipe is then blasted to meet the specified cleanliness and profile level. After Blast the pipe continues to rotate and the ID of the pipe is automatically blown/vacuum cleaned. The transfer system then moves the pipe to a stationary ID inspection/profile check. The transfer system then moves the pipe to a pre-coat rotation station. The pipe transfer system then transfers the pipe to the ID coating station. The coating is applied with a computerized plural component delivery system that is mixed at the coating head for optimum quality and efficiency. The pipe is rotated rather than the application head rotating to also provide the highest standards of application quality. The pipe transfer system then moves the pipe to a post rotation station for a wet film coating check and visual check before sending the pipe to the post cure oven.
The pipe is then transported to a gas post cure oven for final cure of the coated product.
Pipe is then moved to the Final Inspection for all quality checks prior to leaving the mill operations for shipment.