Before

Between

After

AirStream™ Installation Prcess
Pipe Resurfacing and Resin Coating System Process

The following description identifies the most important steps, in the process of a water pipe renovation with the IPL-System™. This description includes the theoretical basis, material, equipment used, and quality control measures, especially in cases of drinking water installations.

The renovation of a drinking water net (hot and cold water) can be divided into the following discrete steps:

Disassembly of the armatures and installation of the various drilling supplies

Construction of a circulation of positive – negative pressure (fore-running and reflux)

Drying of the pipe work system and the incrustations
Mechanical Cleaning

Heating the pipe with preheated air

Coating the pipe

Disassembly of the drilling supplies and installation of the armatures

In the following we deal with the most important cleaning and coating steps.

Step 1) Disassembly of the armatures and installation of the various drilling supplies

Step 2) With pressure tubes and switches, there is a circulation built within the pipeline. The hoses, respectively the single taps, are the fore-runners and the riser in the basement is the reflux where the Vacuum is connected

Step 3) Drying of the pipe system and the incrustations is necessary; because the mechanical cleaning is carried out later with a dry granulate. If the pipe is still wet or moist, there is the danger that the dry granulate will get lumpy and stop up the pipes. These lumps are occasionally very hard to remove. Through our proprietary air stream technique, the encrustations are also partially loosened and therefore easier to remove.
The pipe system is dried with dehumidified, pre-clarified air, at a temperature at approximately 50ºC or 120ºF above the surrounding temperature

Step 4) In order to remove the incrustation from the interior at the pipes, an abrasive granulate is applied with high pressure and vacuum air volume. This process gently cleans the pipes, which have been attacked by the incrustations. This process also works for arches, T-pieces and angles and different valves.
Since the granulate looses its abrading capacity over a longer distance, the mechanical cleaning is started on the lowest floor, at that connection which is the closest to the riser. From there, we work from the ground floor up to the uppermost floor. The dust and the removed incrustations resulting from the cleaning are segregated into a vacuum filter collection unit. An endoscope is used to prove that the pipe has been sufficiently cleaned.
To guarantee a good mechanical adhesion of the plastic in the pipe, the pipeline has to be scaled with a coarse granulate roughness height 40-50 µm. or 2-3 mils. A profile plate test is recommended to measure the interior pipe surface

Step 5) Before the epoxy can be applied, the pipe system must be heated with dehumidified, pre-clarified air, at a temperature approximately 50ºC or 120ºF above the surrounding temperature. This temperature gives the epoxy better flow. A thermostat at the pipe connection controls the temperature.

Step 6) Coating of the pipe with the pressure- vacuum system (Push/Pull System™).
When coating the pipe, it is important that the temperature of the pipe is between 100-120ºF. When the pipe is the right temperature, the epoxy components A and B can be mixed. The mixed epoxy is introduced into a hose which is connected to the prepared pipe. A pressure hose on one end of the pipe forces or pushes the epoxy into the pipe. At the other end a vacuum sucks or pulls the epoxy through the pipes. This Push/Pull System™ supplies a lot of air volume and speed which transports the epoxy through the pipe quickly and evenly. This Push Pull System™ eliminates mistakes in epoxy distribution that are caused by using only pressure or only vacuum. (i.e. uneven thickness or missed areas). A clear pipe installed at the outlet of the pipe shows when the epoxy has completed coating of the pipe. The air flow is then slowed to a minimum so the epoxy no longer travels through the pipes. This helps the epoxy to dry more quickly and cure.

The epoxy is hardened enough to use the pipe after 5 hours. At this time an endoscope is used to insure that the pipe is completely and evenly coated. An ultra sound device is used to measure the thickness of the epoxy coating.

The amount of epoxy used is calculated by using a table. This table takes into consideration the pipe material, length and diameter.Illustration 1: Union of the epoxy after the first and second coating

Step 7) After the epoxy has hardened, a pressure test is done to insure there are no leaks in the pipe. The connecters are then removed and the armatures reinstalled.
The pipes are then operational.The PUSH/PULL-System™ includes a double security in order to assure quality. During pipe renovation we also recognize the following quality assurance measures:

• Endoscope of each cleaning and coating step. It is also possible to understand the course of the pipes

• SPS-checked On-Line-pH-value measuring and surveillance at the flushing-vehicle

• Flow measuring

• Background preliminary treatment in two steps

• All pipes are at least coated twice

• Pressure tests before, during and after the renovation

• Test pipes are installed in the flushing circulation in order to control the flushing value, respectively the degree of purification

• Plastic coating tests: curing time, color test, mix proportions (gravimetric), reaction course

• Water quality before and after the renovation

• Check lists (similar to pilot checks)

• Cleaning reports for documentation

• Site book as an accompanying document before, during and after the renovation

Call, write or email IPL for more information about how the patented IPL AirStream ™ technology can benefit your pipe system.

 

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