And the Polyurea Goes Round & Round:
Robotic Sprayed-in-Place Pipelining

Dudley J Primeaux II, PCS, CCI
VersaFlex Incorporated
Primeaux Associates LLC
dudley@primeauxassociates.com
dudley@versaflex.com

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberWe Are In Trouble!!

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November• In the US alone, it is estimated that over
$1 trillion will be required over the next 25
years just to restore buried potable waterlines due to age / deterioration• In EU, infrastructure is must older and inworse conditions• Above does not include all the burried“chemical pipelines” also affected
References:
Buried No Longer: Confronting America’s Water Infrastructure Challenge, AWWA, 2012.
State of Technology Review Report on Rehabilitation of Wastewater Collection and Water Distribution Systems, EPA, 2012.

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

So what do we do to repair????

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Conventional Methods• Dig up / Replace– Very large “foot-print” / disruption– Very expensive– Not practical in many locations

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Conventional Methods• Dig up / Replace• Pipe Bursting / Jacking– Large “foot-print” for access– Use of steel, PE or PVC pipe
– Covers lateral connections

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Conventional Methods• Dig up / Replace• Pipe Bursting / Jacking• Cementicious Linings– Economical advantage– Not for aggressive (high acidic) applications– Will crack over time / movement– Potential erosion issues

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Conventional Methods• Dig up / Replace• Pipe Bursting / Jacking• Cementicious Linings• CIPP: Cured-in-Place Pipelining– Epoxy or vinyl ester impregnated sock– Covers lateral intrusion, must be cleared– Not good for various pipe diameters in “run”– Annular space
PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

SIPP: Sprayed-in-Place Pipe
• Dig up / Replace• Pipe Bursting / Jacking• Cementicious Linings• CIPP: Cured-in-Place Pipelining• SIPP: Sprayed-in-Place Pipelining– Epoxy, Polyurethane or Polyurea– Lateral tie-ins remain cleared– Accommodates various pipe diameters– No annular space
PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Spray PUA Lined Pipe
• Pipe Rotation / lance spray head
• Simple “robotic head”• Limited to pipe joint sections• Difficult in bends and elbows

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Spray PUA Lined Pipe
• Pipe rotation

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Spray PUA Lined Pipe

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Spray PUA Lined Pipe
• Simple “robotic head”– “Clemco” based equipment

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberBut wait a minute……

How do you rotate the pipe once installed?

What about the joint areas????

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberSo how do you line “in-place” pipe withPolyurea Spray?

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November• Hand spray application– Pipe must be large enough to enter, or havereally small spray applicators

Armco Culverts, Australia, 1999.

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Background / History• First disclosed in 1989
– AL 8824 Patent Suggestion, Texaco ChemicalCompany• Subsequent work in UK in mid 90’s
– Shot independent streams of ISO component
and Resin component, mixed on “spinner”
PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Background / History• First “spinner” application in 1992
– PUA dispensed from impingement mix spray gun on spinning disk
– Used in some manhole lining work
– Limits entrance in confined space

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Background / History• First Commercial Use – 1995
– Southern Underground– Waste water pipeline• Houston, Texas– Not a 360° coverage / bottom bare
– Large diameter / ride-on unit

ICI Polyurethanes Review, Vol 6, No 8, October 1996

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Background / History• “Spinning” spray gun technique– Great concept for fast set– Minimum diameter 60 cm (24 inch)– Wheels track in fresh material

Rotating impingement
mix gunUS Patent 6,632,475

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberCurrent Robotic Technology• “Spinning” disk / cup– Premixed system dispensed and broadcast off– High RPM disk or “cup” - up to 30,000 rpm’s– Oscillation / reciprocation simulates “hand spray”– Segmented “head” for bends and 90°

US Patent’s 6,986,813; 7,338,687; 7,591,901; 7,682,655

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberCurrent Robotic Technology• Static Mix / Hollow Cone Spray– Spray pattern not perpendicular, double run

Adjustable from 25 – 60+ cm (10 – 24”) via skid
PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberCurrent Robotic Technology• Typical installation diagram– Surface preparation is similar setup– CCTV’s observe real-time installation– Automatic hose real controls speed / application filmbuild

PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberCurrent Robotic Technology• Robotic Pipe-Lining Rehabilitation– Technology introduced in 2000, but slow to start– Robotic Spray-In-Place Pipe (SIPP)– Up to 200 meters in-place, 2.5 cm to 2.5 m diameter– Municipal or Chemical plant use– High pressure rating• 76 mm dia hole, 6 mm thickness, > 2.8 MPa pressure hold

– Can line multiple diameters in-line, bends and elbow’s– Class IV Structural capabilities

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Types of Polyurea

Flexural Modulus, MPakpsi
Tensile strength, MPa
kpsiElongation, %Hardness
Gel time, sec“standard”

SemiStructuralFully
Structural~ 345~ 50~ 13 – 20
2–3
400
50~ 690~ 100~ 20 – 34
3–525058> 1725> 250~ 28 - 41
4-6< 20656 to 86 to 86 to 8*- relative unlimited applied film thickness* One supplier example is actually 60 sec gel / modified aliphatic / aromatic PUA, limited film thickness
PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Types of Polyurea
Industry Uses

“standard”

SemiStructural

Potable water
Wastewater
Process water / salt
Power generation
Chemical plants
Low pressure steam
Oil sands
Mining / processing
Deteriorated pipe

yes
yes
yes
yes
conditionalnoyesconditional
no

yes
yes
yes
yes
yes
yes
yes
yes
conditional

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Fully
Structural
yes
yes
yes
yes
yes
yes
no
no
yes

Recent Advancements• Electrostatic Deposition– Uses a slower set PUA system– Designed for smaller diameter pipe
• Down to 2.5 cm (1-inch) diameter– Insures complete, uniform coverage– Can be adapted to large diameter pipe for fastset PUA systems

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Recent Advancements• Electrostatic Deposition– Based on self generating charge equipment• US Patented work:– 7,992,514 and 8,109,231
PDA Europe 2012 Annual Conference –Istanbul, 12-14 NovemberIndustry Standards• ASTM International– Work Group WK23937 (F 36), Standard Practice for
Renewal of Existing Potable Water Pipes by Spray inPlace Pipe – Polyurea and Polyurethane Coatings• Calculation for required applied thickness based on material
properties and pipe diameter• ASCE: American Society of Civil Engineers– Manual of Practice 28: Methods for Renewal ofPotable Water Pipes

PDA Europe 2012 Annual Conference –Istanbul, 12-14 November

Conclusion
Polyurea is sound solution for pipeline
rehabilitation work: State-of-the-Art– Proven, not experimental– Conforms to pipe interior surface / no annulus– Fast set allows rapid return to service– Thickness builds in single run– No solvents, minimized fire issues– Various industrial projects in-process now

Around the Globe!
PDA Europe 2012 Annual Conference –Istanbul, 12-14 November