Cost Effective and Long Term Solution for Flange Protection

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Flange Protection System

The ChallengeThe annular gap around a flange joint is highly vulnerable to the ingress of debris and moisture that can result in degradation and cause corrosive damages to the flange, sealing faces, nuts and bolts. Excessive corrosion in these areas is hazardous, and replacement could mean unscheduled downtime forthe machining or replacement of damaged components.

The Advantages Immediate 30% to 40% cost savings on maintenance and replacements, reduces time spent on regular inspection and maintenance

Extends the useful life of nuts and bolts

Eliminates the need for time consuming and destructive removal procedures

Reusable and can be easily inspected

The SolutionTo combat these problems, IOSSB has developed an inexpensive, effective and long lasting Flange Protection System that provides total protection from corrosion and foreign materials. These can be installed without the need for splitting or separating the joint.

Our corrosion prevention technology is jointly patented with PETRONAS for riser clamps, flanges, valves,nuts and bolts. All of our products are developed and manufactured in-house with first-rate product quality control. Our integrated Flange Protection System and management includes installation of:

CorroCap FlangeShield Bolting and Tensioning Services

We also provide other related services such as valve servicing and replacement.

An immediate30% to 40% cost saving

APPLICATIONInstallation is simple and easy as the caps can be pressed onto the nuts and bolts. Made of durable silicone rubber, CorroCap has been designed and manufactured to meet the harsh conditions of offshore environments.

More importantly, it eliminates the need for time consuming and destructive removal procedures suchas the use of hack saws and cutting torches during maintenance. Furthermore, bolts and nuts are easily inspectable because CorroCap can be detached and attached repeatedly with minimal effort.

Industrial nuts and bolts are difficult to protect because of their odd shapes and restricted accessibility. Fluorocarbon coating has been used as an alternative but this too has proven to be inadequate as it cannot prevent mechanical damage.

CorroCap possess ideal characteristics that make it the obvious choice in nut and bolt protection. It incorporates a unique one-way valve that allows air, water and excess inhibitors to escape, creating a near vacuum seal hence protecting the nuts and bolts in a corrosion free environment.

To provide long term corrosion protection, CorroCap is installed along with DP-180 a formulation of modified waxes containing corrosion inhibitors. When applied with DP-180 and Corro-Cillin a rust converting and preventing agent, CorroCap offers total solution to the mitigation of bolts and nuts corrosion.

BENEFITS Made from top quality non-flammable silicone rubber under stringent quality control

Flexible, reusable and designed to fit nuts and bolts sized between 0.5 inch to 3.5 inches

18 available sizes available to fit clients preferences

Will not harden under long UV exposure

Able to withstand heat ranging up to 150C or more upon special request

Immediate cost savings of 30% to 40% on maintenance & studbolt replacements

Extends the useful life of nuts and bolts

Reduces time spent on regular inspection and maintenance

CorroCap Product Characteristic Characteristics Value

Linear Shrinkage (%) 3.8

Hardness (JIS) 50

Tensile Strength (MPa) 8.8

Elongation (%) 350

Tear Strength (kN/m) 13

Compression Set (%) 10

Dielectric Strength (kV/mm) Dry 24 Wet 20

Volume Resistivity (/cm) Dry 8 x 1014 Wet 5 x 1014

Controlling corrosion on flanges is an important operational task in the industry as multiple crevicesand annulars spaces exists in the body of the flangeand at the sealing faces. Nuts and bolts are exposed to mechanical damage during assembly and are difficultto coat as adequate surface preparation is virtually impossible.

The FlangeShield employs a non-toxic, non-flammable, non-VOC (Volatile Organic Compound)and environmentally safe material a rust converting compound designed specifically for use in the marine environment. The material is pre-heated to lower its viscosity which will allow it to penetrate into allthe crevices.

FlangeShieldBENEFITS Wax-based, non-toxic, non-flammable, non-VOC (Volatile Organic Compound) and environmentally safe protection for flanges

Protects crevices, annular spaces from corrosion

Offers total and long lasting protection for flanges, nuts and bolts when used with CorroCap

APPLICATIONBy utilizing IOSSBs FlangeShield, the material is injected to temporarily fill voids in the flange. Excess material is sucked out, leaving a protective coating between 1-3mm.

The flange can be easily inspected after the procedure and when used with CorroCap,the system offers total protection for nuts,bolts and flanges.

A total and long lastingprotection for nuts,bolts and flanges

FlangeShield Material Safety Data Sheet DP-100

PRODUCT NAME DP-100 Rust Preventive Wax Compound

INGREDIENTS Substance Formal Name Mixture of Petroleum Hydrocarbon

COMPOSITION / CAS Number, % by weight: 8009-03-8 80%

INFORMATION 8002-74-2 20%

HANDLING When using do not eat, drink or smoke. Only use in well-ventilated areas. Avoid contact with the skin, eyes, nose and mouth, especially when the product is molten. Wash all exposed skin before eating, drinking, smoking or using the toilet.

STORAGE Do not store in unsuitable, unlabelled or incorrectly labelled containers. Molten product in storage tanks should be blanketed with nitrogen.

STABILITY/REACTIVITY Stability Stable.

Melting Melting temperature should not exceed 140C. Over heating may cause oxidization.

Conditions to avoid Naked flames.

Materials to avoid Strong oxidizing agents.

Hazardous decomposition products None known.

HAZARDS IDENTIFICATION Human Health Hazard Molten wax causes serious burns if skin contact occurs.

Safety Hazards Combustible.

Environmental Hazards No specific hazards.

FIRST AID MEASURES Symptoms and Effects Molten wax fumes may be slightly irritating to the eyes and upper respiratory tract irritation if inhaled. Molten wax will cause burns on contact with skin.

First Aid Inhalation Remove to fresh air. Seek medical attention.

First Aid Skin If hot wax strikes the skin, drench or immerse the area in water to assist cooling. If available, apply iced water or iced packed to the burned area (DO NOT USE iced water or cold packs if the burned area covers more than 10 percent of the body, as this may contribute to shock). Do not try to remove wax from a burn after it has cooled. Seek medical attention. If cool wax contacts skin, wash the area with warm soapy water.

First AidEye Hold eyelids open and flush eye with water. Seek medical attention.

First Aid Ingestion Obtain medical attention.

Advice to Physicians Treat symptomatically. Diagnosis of ingestion of this product is by the history of events.

Bolting and TensioningWe offer hydraulic bolt torqueing and tensioning solutions for offshore platforms, pipelines (subseaand onshore) and oil and gas terminals. Services include removal, replacement, freeing and retightening of studbolts.

Our hydraulic bolt torqueing and tensioning systems are among the best tightening methods to help control the significant costs resulting from incorrectly tightened studs.

PROVEN EFFICACYIn 2004, IOSSB installed the CorroCap for a clients Platform located offshore of Sarawak.

A post-application survey was conducted after6 years and the protected nuts and bolts show no signs of corrosion.

The anticorrosion compound was found tobe still present on the nuts and bolts.

Visuals inspections indicate clear comparative advantage of our protection system against conventional fluorocarbon coating.

Unprotected Protected

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Innovative Oilfield Services Sdn Bhd (383695-M)

Headquarters B07-G, Paragon Point 1, Jalan Medan PB5Medan Pusat Bandar 5, Seksyen 9Pusat Bandar Baru Bangi, 43650 BangiSelangor Darul Ehsan, MALAYSIA. Tel: +6 03 8926 1261Fax: +6 03 8926 1263 Email: admin@iossb.com.my

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Innovative Manufacturing Services Sdn BhdNo.8, Jalan 8/16Taman Industri Selaman, Seksyen 1043650 Bangi, Selangor Darul Ehsan, MALAYSIA.Tel: +6 03 8926 1264