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Jan 13, 2016  Düsseldorf / Germany

Loctite launches reference application in Henkel Headquarters in Düsseldorf

Henkel and Xervon demonstrate the Loctite Repair System in real life

Loctite, the solution provider for adhesives, sealants and protective coatings within the Henkel Group, and the German maintenance service provider Xervon have repaired pipelines in the home factory at Henkel’s headquarters in Düsseldorf (Germany) using the new Loctite Composite Repair System. The innovative system increases pipe lifetime by up to 20 years. Another advantage is that pipelines can be repaired without interrupting operations, thus avoiding the often high costs associated with unplanned shutdowns.

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???gallery.open.slideshow??? The Henkel plant in Düsseldorf

The Henkel plant in Düsseldorf is criss-crossed by 18 kilometers of piping bridges and 300 kilometers of pipelines.

???gallery.open.slideshow??? The Henkel team with a piping bridge of the Düsseldorf main plant

The Henkel team with a piping bridge of the Düsseldorf main plant in the background. This section is being maintained using the Loctite Composite Repair System.

???gallery.open.slideshow???  Experts from Henkel, Loctite and Xervon inspecting the repair work.

Experts from Henkel, Loctite and Xervon inspecting the repair work.

???gallery.open.slideshow??? Application of the first layer of Loctite PC 5085 glass-carbon fiber tape

Application of the first layer of Loctite PC 5085 glass-carbon fiber tape.

???gallery.open.slideshow??? The tape is pre-impregnated with the two-part epoxy resin Loctite PC 7210

The tape is pre-impregnated with the two-part epoxy resin Loctite PC 7210. After application, the layers are wrapped around with a peel ply tape to enhance both the performance and the appearance.

???gallery.open.slideshow??? The execution of the repair work is closely inspected for quality

The execution of the repair work is closely inspected for quality.

???gallery.open.slideshow??? Application of Loctite PC 7255 as corrosion protection

The final step in the Loctite Composite Repair System is the application of Loctite PC 7255 as corrosion protection.

???gallery.open.slideshow??? Protective topcoat of Loctite PC 7255

The protective topcoat of Loctite PC 7255 must be at least 500 micrometers thick.

???gallery.open.slideshow??? The pipeline is protected against corrosion for at least 20 years.

The pipeline is protected against corrosion for at least 20 years.

The Henkel plant in Düsseldorf is criss-crossed by 18 kilometers of piping bridges and 300 kilometers of pipelines. Maintaining these steel pipelines and repairing any leaks quickly, safely and sustainably is a top priority for the operator. The Loctite Composite Repair System restores even heavily corroded pipes to an as-new condition and can extend their lifetime by up to 20 years.

“20 years is the target timescale – also for competitor products. But we are confident that the Loctite Composite Repair System can last far beyond that period,” says Carsten Sperlich, who heads the Technical Infrastructure department at the Düsseldorf site and is thus responsible for ensuring the pipe bridges are in perfect working order. “The new system is very interesting for us because it means that we can repair corroded pipelines without interrupting operations, which eliminates the costs that would be generated by unplanned shutdowns of production facilities.”

Repair rather than replace

For the pilot project, a ten-meter long section of piping was repaired with the Loctite composite system. Traditionally, the user would have to replace that pipe section. “With the innovative repair system from Henkel, the piping is as good as new,” says Bernd Hammer, Global Market Development Manager for Oil & Gas and Refineries at Adhesive Technologies. And this is how it works: The surface of the defective pipe section is cleaned by sandblasting. Next, Loctite SF 7515 is applied as a temporary corrosion inhibitor. The backbone of the repair system is laid by wrapping the pipe with several layers of high-strength glass-carbon fiber tape Loctite PC 5085 which has been pre-impregnated with the two-part epoxy resin Loctite PC 7210. Finally, several layers of topcoat Loctite PC 7255 are applied as corrosion protection. The Loctite Composite Repair System has been certified by DNV GL in accordance with the global quality standard ISO 24817. The method has also been approved by Lloyds Register, in conformity with the ASME PCC-2 standard, and by TÜV Rheinland.

Penetrating markets together

The company Xervon applied the Loctite Composite Repair system to the pipelines in the Henkel plant. This enterprise, headquartered in Cologne (Germany) is one of a select number of service providers that Henkel works with in its “Henkel Certified Applicator” network. Before beginning the project, Xervon employees received extensive training in comprehensive seminars. The Loctite Composite Repair System is being used worldwide in refineries, petrochemical plants, power plants and water treatment systems. Since existing production plants are reaching an age when they require a general overhaul, the interest in the repair system is correspondingly high. “That’s why it was so important to apply the system in our own Henkel plant. We can present this in-situ reference project to our customers and also monitor it over the long term, allowing everyone to see for themselves the level of quality this repair provides,” says Bernd Hammer from Henkel.