TPT November 2020

AR T I C L E

Allied PhotoChemical

⇒ Smaller – ~ 80% less coating shipped into plant/less overall handling – Less overall floor space consumed – No work-in-process – coat, then immediately cure – Lower energy costs (UV lamps vs induction heating) – Lower cost of quality ⇒ Cleaner – UV has no VOC’s or HAP’s – sustainable – Less permitting required for UV coatings – No uncured or wet coating post-process 4.0 – Return on investment Cost per linear foot comparison – water-based vs UV coating (see table 3) 5.0 – Process solution/equipment Based on the results of the testing and cost analysis, the customer made the decision to implement a new UV coating system (pictured below), which was being installed at the time this paper was written. Note that the pipe flow is from left-to-right and that the infrared oven is only utilised at temperatures below 55°F. Total system width is around 21ft.

The proof is in the pictures:

Picture 1: ASTM B117 Salt Fog – 48 hours UV vs water-based at 1.0 and 0.6 mils dry film thickness

Picture 2: ASTM B117 Salt Fog – 312 hours UV vs water-based at 1.0 and 0.6 mils dry film thickness

3.0 – Process improvements UV process advantages: ⇒ Faster – Increased line speed – typical range of 20 to 40% – Instant cure – minimal humidity and temperature issues – No uncured or wet coating post-process

FUNCTIONAL PIPE COATING MODEL Linear Foot Comparison

9.625 Inches diameter

Target Coating Thickness

1.0 Mils thick

Picture 3: OCTG UV System – Courtesy of Terrell Manufacturing Systems (www.terrellmanufacturing.com)

Description

Water-based

UV

Coating cost per gallon

$11.89 18.5% 81.5%

$39.70 100.0%

Per cent solids Per cent water

0.0% 1,604

Coverage at 1 mil – square feet Coverage at 1 mil – square inches Diameter of pipe (inches) Linear inches per gallon Linear feet per gallon @ 1 mils thick Linear feet per gallon @ 1.0 mils thick Cost per linear foot coated specificed inch diameter pipe

297

42,731 30.24

230,976

30.24 7,639

1,413

118

637

118

637

$0.101

$0.062

Water-based Cost

UV Cost Savings

Linear Feet Run

UV Cost

2,000,000 million linear foot run

$201,931.82

$124,734.08

$77,197.74

10,000,000 million linear foot run $1,009,659.09

$623,670.41 $385,988.68

20,000,000 million linear foot run $2,019,318.18 $1,247,340.82 $771,977.36 Table 3: ROI for water-based vs UV coatings – OCTG per linear foot Source: https://www.alliedphotochemical.com/roi-calculators/

Picture 4: Black UV coated OCTG pipe Courtesy of Allied PhotoChemical, Inc

69

www.read-tpt.com

NOVEMBER 2020