CONCORTAPE

High performance pipe - wrap tape coating

Protection For: oil gas water sewerage chemical Pipelines

Specially formulated coal tar tape-wrap coating for ultimate pipeline protection against: Galvanic Corrosion Cathodic Disbondment Microbiological Corrosion Stray Current Corrosion Impact Abrasion Shear Stress Soil-Electrolytes UV & Moisture

CONCORTAPE : Product Description

CONCORTAPE protective pipe wrap tape coating fulfils all obligations towards pipeline protection. i.e being resistant to environmental, mechanical, chemical and microbiological damage from the initial stage of handling, installation to its entire service life. All this at a very reasonable cost compared to competitive technologies and products. CONCORTAPE, is a specially formulated coal tar based plasticized compound re-enforced with a synthetic FRP substrate or mesh fibre. This proprietary technology dispels all myths related to coal tar coating. viz. problems related to disbondment (even if cathodically protected),sagging, cracking, shear resistance, microbiological corrosion, oxidation etc. The specially formulated tapes enhances the proven track record of coal tar, a known and proven anti-corrosive material giving almost equivalent performance- attributes obtainable from other upcoming technologies at a sizably reduced cost and economy. B.M.CONCOR is a company promoted by Dr. M. Sen, a pioneer in the field of introducing coal tar tape coating in India. The company has a fully equipped laboratory to carry out all the tests required as per the relevant AWWA, BS and BIS standards related to coal tar tape coating. The company's product CONCORTAPE conforms to AWWA-C203 & BIS-153372003 standards.

Works

Product

Application : Preparation

CONCORTAPE USP
Quality : Organizations like AWWA, BIS have setup stringent standards to ensure quality of product like AWWA-C203 & BIS-15337-2003 standards. BIS has specifically initiated standard IS-15337-2003 to ensure the quality of coal tar tape. The compliance to this standard is most important to fulfill the high performance attributes of coal tar based tape coating and to eliminate the use of low quality/cost material. CONCORTAPE adheres to this standard and in the process it always tries to convince its clients to the importance of this standard. Cost : The true cost of any pipe coating system is not just the applied cost per square metre. The true cost is the sum of :
Application : Wrapping

Application : Priming

True cost = Materials cost + Application cost + Maintenance cost. Therefore the total cost should cover the initial cost of coating, installation, joint coatings and repairs. This should be calculated taking into account transportation, handling, installation losses for a given coating. The final derivative has to be assessed with the total service life of that coating. CONCORTAPE guarantees a sizable cost benefit over other coating products when this total equation is taken into consideration.

Coated Pipe

CONCORTAPE : Features & Benefits

Excellent resistance to environmental, mechanical and microbiological damage. Excellent performance from initial stage of handling and installation, to its entire service life. Most reasonable cost compared to today's competing technologies and products. Compliance to most stringent test parameters AWWA-C203, BS-4164 and BIS-15337(2003) specifications. Negligible damage during transportation, handling, storage and installation of the tape coat. Ability to be quickly and efficiently applied and/or repaired in-situ. Excellent resistance to soil-stress and water absorption in all soil types and backfill. All weather coating protection even in extreme environment and varied and difficult terrain, including rocky terrain. Excellent di-electric strength which works in synergy with supplemental cathodic protection, reducing the cost in process. Excellent adhesion to various surfaces like mild steel, ductile iron, concrete, etc, which is the prime requirement for resisting corrosion. Excellent resistance to MIC (microbiologically induced corrosion) especially Sulphate Reducing Bacteria (SRB). Excellent performance attributes like hardness, adhesion, flexibility, water repellence and resistance against abrasion, impact and soil electrolytes. Compliance to IS 15337-2003, the latest National standard in INDIA of relevance, which BIS has specifically brought out in 2003, to ensure quality of coal tar tape.

Consumption of Concortape (in sq. metres per kilometre of pipe length)

Figures given are for overlap of 12.5 to 13 mm. except those given in bracket are for overlap of 25 mm. wastages are also included in these figures. PipeNB (mm) 80 100 150 200 250 300 PipeOD (mm) 89 114.3 168 220 270 324 100 344 (400) 444 (516) Tape Width (mm) 125 166 200 338.5 (376) 433 422 (483) (455) 636 (710) 832 (930) 618 (670) 810 (875) 994 (1074) 1193 (1290) 610 (650) 800 (852) 980 (1045) 1176 (1255) 250 780 (830) 957 (1017) 1149 (1220) 333 933 (990) 1120 (1188)

Note Preferably tape width should be close to or smaller than the pipe O.D. Above quantities correspond to straight length of pipe. For bends & fittings additional provisions are to be kept. For pipes having O.D. higher than 324 mm., tape required can be estimated at 110% (for 12 - 13mm. Overlap) and at 116% (for 25 mm. Overlap) of the actual pipe surface area to be protected.

CONCORTAPE
High performance pipe - wrap tape coating
Application Areas
CONCORTAPE application covers a wide spectrum of areas encompassing oil, gas, power, utilities, chemical, etc. PIPELINES Coating of steel, ductile iron, concrete pipes (buried, overground, marine) carrying oil, gas, water, wastewater, chemical, etc. Protection of joints, bends, couplings, saddles, valves, cathodic protection lugs and connections. Rehabilitation of failed/damaged coatings. CHEMICAL PLANTS Protection of structures exposed to corrosive environments of hydrochloric acid, sulphuric acid, nitric acid, chlorine, salt, alkalis, ammonia, etc. SHIPPING Protection of steel pipes/structures of cargo ships and oil tankers. OIL EXPLORATION Protection of riser pipe/structures in offshore rigs.

Please contact us for detailed Product Specification and other technical information.

B. M. CONCOR & CO.

P-15, BAURIA INDUSTRIAL ESTATE, P.O. CHAKKASHI DIST. HOWRAH 711307 WEST BENGAL, INDIA
www.bmconcor.com

Enclosure - 1 Typical Specification of CONCORTAPE B Compound Reinforcement Separator Thickness Width (mm) Average Weight Compound :Softening Point (R & B), degC Needle Penetration at: (25 degC/ 100gms/ 5secs, 10mm) Filler Content, w/w % Adhesion Test ( to be conducted at least 72 hours after application) Holiday Test Voltage Formulated Anticorrosive Compound with condensed hydrocarbon of coal tar origin as carrier Synthetic Substrate such as FRP Tissue reinforced with glass Plastic (to be removed) As desired between 2.0 mm to 4.0 mm with tolerance of plus minus 10% 166, 200, 250, 333, & 500 with tolerance of plus minus 10% 1.5 kg / sq. metre / mm. thickness minimum

Between 65 & 121 Between 0 & 20

Between 20 & 30 Passes Test as per IS 15337 2003 (Sec. 7.1) OR AWWA - C 203 (Sec. 8.8) Between 10 kV and 15 kV depending on tape thickness as per IS 15337 2003 (Sec 7.2) OR AWWA C203 91 (Sec 6) Passes Test as per IS 15337 2003 (Sec 7.3) OR AWWA C 203 91 (Sec 7.7.1) 95 % w/w minimum 60 Maximum In rolls of 10 metres length for 2.0 mm thick tape and in rolls of 5 metres length for other thicknesses. Rolls wound around a paper core. To be handled carefully and stored vertically in card board boxes in stacks of maximum three boxes stack height. To be stored under a shed away from direct sun & any source of flame.

Direct Impact Test

Insolubility in Petrol (after immersion for 24 hours) Service Temperature , deg C Supply

Storage

for B.M.CONCOR & CO. Dr. M. Sen Mobile : +91 9433878772

Enclosure -2 Typical Specification of Synthetic Primer CONCORSOL B

Type Drying Time, minutes (Touch Dry) Flash Point (Abel), deg C minimum Viscosity (Flow Time at 23 deg C No. 4 Flow Cup ), secs Volatile Matter (105 to 110 deg C), Percent loss by weight, maximum

Fast drying, Synthetic, Solvent based containing Rubber, Resin & Plasticisers 5 to 15 23

35 to 60

75

These shall be liquids that can be applied without heating and shall produce an effective bond between the surfaces to be protected and the subsequent coating of the tape CONCORTAPE - B. The solution shall not settle in the container to form a cake that cannot be mixed easily by hand stirring. They shall have good spraying / brushing properties and a minimum tendency to produce bubbles during application. AWWA standards recommend that both the primer and the tape it is meant for, shall be manufactured by the same manufacturer for getting effective bonding. This primer conforms to British Standard BS 4164 1987 and Bureau of Indian Standard IS-153372003 and AWWA-C 203-1991. for B.M.CONCOR & CO.

Dr. M. Sen Mobile : +91 9433878772 ********

Enclosure 3 - Promoter Background

The Company B.M.CONCOR & CO. has been promoted by Dr. Milan Sen, who holds a Ph.D degree in Chemical Engineering from London University. He is a Fellow of the Chemical Society of Great Britain and is a member of Institution of Chemical Engineers (U.K). Over a career spanning for more than 40 years covering Project Engineering, Design and Construction of Chemical & Petrochemical industries in India, U.K and France, he has around 20 years of specialized experience in the anticorrosion protection of underground pipelines. Dr. Sen had been a pioneer in this country in the field of protection of buried pipeline with Coal Tar Tape. Which he introduced under the name of Corprotex (India) Pvt. Ltd., which brought into India the concept of protecting buried pipelines by Coal Tar Tape, protection by such type of tape is very much in vogue now in this country. Major Clientele serviced were :Oil & Gas Sector : Indian Oil Corporation (Pipeline, Marketing, & Refineries divisions), Oil & Natural Gas Corporation Ltd. (ONGC), Oil India Ltd., BPCL, HPCL, Assam Oil, Gas Authority of India Ltd., British Gas / Calcutta Gas. Refineries : Chennai Petroleum, Cochin Refinery, Panipat Refinery, Haldia Refinery, Barauni Refinery. Petrochemical Sector : Haldia Petrochemicals, Indian Petrochemical Ltd (IPCL) Dahej, Bongaigaon Refinery & Petrochemicals. Power Sector : NTPC, BHEL, Damodar Valley Corpn.(DVC), Neyville Lignite, West Bengal Power Dev. Corpn., Gujrat Electricity Board. Steel Plant : Rourkela Steel Plant, Durgapur Steel Plant, TISCO. Others : Hindustan Zinc Ltd., Calcutta Metropolitan Dev. Authority (CMDA), Calcutta Metropolitan Water & Sanitation Authority, Public Health Engg. Coal Tar tapes produced by Dr. Sen were well established and accepted by : Consultants : Engineers India Ltd., Project India Development Corporation Ltd., M.N.Dastur & Co., Development Consultants Ltd., MECON and many others. Contracting organisations : Larsen & Toubro, Punj Lloyd Ld., Toyo Engineering, Techno Electric, Bridge & Roof, Stewarts & Lloyds, Daelim of South Korea, Lurgi, etc. International Lead Assessors : Lloyds, Bureau Veritas, DNV, Certification Engineers International etc. The tape produced and supplied by Corprotex under the expertise of Dr. Sen had already been and were being used to the extent as mentioned hereinbelow (some major ones are being mentioned): Sq. metres -- Indian Oil Corporation : 653220 -- ONGC 127665 -- Refineries 30160 -- Haldia Petrochem / IPCL 175000 -- GAIL / British Gas & Cal Gas 26000 -- Hindustan Zinc ltd., 130000 -- Chambal Fertilisers 30000 -- NTPC 49700 -- DVC/BHEL/ W.B.Power Dev. Corp 40000 -- Civic Authorities 71000

While many more are there, some of the jobs worth mentioning completed with Coal Tar Tape produced by Dr. Sens efforts are mentioned herein below which used the tape after getting convinced about its suitability. : The 1500 mm dia arterial underground pipeline of 9 km length of Calcutta Metropolitan Dev. Authority starting from TALA TANK to AUCKLAND SQ. reservoir under World Bank supervision. This, like few other lines, is providing treated water for Calcutta. About 58 kms (in two phases) of a 16 inch water line (a lifeline) of Hindustan Zinc Ltd starting from a reservoir to Agucha Mine Township of HZL under EILs recommendation. Indian Oil Pipeline Division had used this tape in refurbishing & maintenance of their crosscountry oil & petroleum products pipelines.( more than about 470000 sq. metres have already been used.) The buried pipelines in ONGCs Uran Splash Zone were refurbished by this tape under EILs recommendation. Chambal Fertilisers in M.P. got rid of old coatings of all buried pipelines in their complex (supplied by a foreign company) and recoated with this tape. Underground pipelines in the Utility section of Haldia Petrochemicals and partly in their cracker complex were protected by this tape. NTPC had selected this tape for protecting important underground pipelines in their Talcher, Farakka, Unchahar STPP plants. Unfortunately, due to betrayal & connivance of his partner under the external interference from an unscrupulous outsider, the Corprotexs operation ceased to function from October, 2004 and the Company had remained in-operative & de-facto closed since then. Under the circumstances Dr. Sen had started this present Company B.M.CONCOR & CO on his own and the tape that is going to be produced will be at least identical if not superior & of improved type. *********

Enclosure 4
How to Ensure Quality of Coal Tar Tape & its compliance to IS 15337 2003

In the past because of inconsistencies (primarily because of use of bitumen or low quality coal tar, which is used for lower pricing) in the performances of some so called Coal Tar Tape Coatings, Bureau of Indian Standards have brought out & published the Standard IS 15337 2003 to ensure (to the extent possible) usage of right quality of coal tar in the formulations of Coal Tar Saturants. This was essentially done to ensure use of quality raw material so that the final product can give optimum protection, especially is respect to adhesion and resistance to microbiological corrosion and cathodic disbondment. It is advisable that the End Users or their Consultants, be very watchful & vigilant with 100% control by themselves independently while conducting the following testing as per IS 153372003 : To check Holiday Test as per Clause 7.2 of the said standard. To check Adhesion as per Clause 7.1 of the standard. To check Insolubility in Motor Spirit conforming to IS 2796 2000 as per Annex C of the Standard. Here care must be taken to ensure the quality of the Motor Spirit and the sample to be tested under their totally own control. To check the resistance of the tape coating against Cathodic Disbondment and Microbiological corrosion through periodic testing as per the Annex D and Annex E of the said standard respectively Passing of these two tests will ensure the righteous nature of the coal tar compounding, which is the primary requirement in such type of coating.

********

Enclosure 5 Advantages of Coal Tar for pipeline protection

Importance of Coal Tar materials as coating materials for buried piping 1. Buried piping has to withstand always not only the galvanic (or electrochemical) corrosion but also the following : -1. Corrosion from microbiological organisms or bacteria that is present in the soil in all environments. 2. Stress Corrosion Cracking. 1.1 With regard to microbiological corrosion, the bacteria of relevance are Anaerobic bacteria (which act in absence of air) and Aerobic bacteria (which act in presence of air & water). a) Anaerobic bacteria which grows in reducing conditions mostly produced in wet, boggy soils & marshes (most common variety is the Sulphur Reducing Bacteria or SRB) reduce the sulphates (present in the soil) to sulphides. Presence of sulphides affects both cathodic & anodic reactions occurring on iron surface. They usually retard cathodic reaction particularly hydrogen evolution and accelerates anodic dissolution of iron and hence increased corrosion. b) Aerobic bacteria such as Thiobaecillus, ThioOxidants in presence of air / oxygen are capable of oxidizing elemental sulphur or sulphur bearing compounds to form acid:-2 S + 3 O2 + 3 H2 O >> 2 H2SO4 They are formed at low pH and can form Sulphuric Acid which can create very corrosive environment. c) Above bacteria in pip soils can consume asphalt or low quality condensed hydrocarbons having predominantly aliphatic i.e. linear or cyclic hydrocarbons. 1.2 Stress corrosion cracking is a possibility when the pipeline is passing through an area which is receiving high voltages from overhead Rail or Tram Traction lines passing through the earth. 2. Coal Tar had been the accepted standard for pipeline coatings since its performance records on underground pipelines have been so far unequalled by any other product -- results all over the world still speak for itself. For using it in the tape form not any grade of coal tar can be used. In this connection what is required is a special quality of coal tar pitch. After high temperature carbonization of coal this specialized grade of Coal Tar Pitch is derived by a series of processing steps to have extremely high percentage of Aromatic Hydrocarbon content (Carbon to Hydrogen ratio). This high aromatic content is mainly responsible for much better performance with regard to :- Effective resistance against electrochemical corrosion & high water resistance. High resistance against equally damaging microbiological corrosion. Very little failure against electrical stress corrosion cracking due to high dielectric strength. Moreover, such type of coating weathers by surface hardening through loss of oils. Hence, plasticizing agents are added in the formulation which are retained after long exposure and give rise to better adhesion to the pipe. Low quality Coal Tar & Petroleum Asphalts which contain predominantly aliphatic & cyclic Saturated Hydrocarbons cannot be expected to provide the above mentioned desired characteristics. Hence, if Coal Tar tapes are manufactured with right chemistry and having high quality components, they can be expected to give effective protection.

Enclosure 6 Comparison of Concortape with other coatings CONCORTAPE-B vs Coal Tar Enamel
CONCORTAPE is more advantageous over coal tar enamel due to the following. Absence of environmental and safety hazards. Uniformity of coating all around the pipe surface. Ease of applicability. Fast curing and faster in application. Lesser involvement of application manpower. Manufactured under controlled plant conditions.

CONCORTAPE-B vs Plastic tapes

CONCORTAPE is more advantageous over plastic tapes due to the following. Cost savings of more than 50% to 60%. Higher tensile strength. Higher impact resistance to mechanical stress and abrasion. Higher resistance to damage during backfill. Can be applied and repaired in-situ. Negligible damage during transportation and installation.