Zap-Lok Pipeline Connection System
General introduction
For over 40 years, the Zap-Lok connection method has been employed in a variety of onshore and offshore applications for the safe and reliable transportation of crude oil, natural gas, gas liquids, carbon dioxide, water, and other commodities. Typical applications include gathering and distribution systems, transmission lines and specialized pipe installations. Tens of thousands of kilometers of steel pipe have been joined using the Zap-Lok process under a wide range of operating conditions. Zap-Lok pipe joining machines have performed on virtually every type of terrain, under severe weather conditions and in hostile environments. They have been used to install portions of offshore pipeline systems and in joining both internally and externally coated pipe. The Zap-Lok method can be used to join thin wall pipe which cannot be easily welded; and due to the fact that no heat is required in the connection process a coated Zap-Lok joint can host corrosive fluid without the corrosive vulnerability of threaded couplings, or damaged internal coating resulting from high temperature produced by welding.
For over 40 years, the Zap-Lok connection method has been employed in a variety of onshore and offshore applications for the safe and reliable transportation of crude oil, natural gas, gas liquids, carbon dioxide, water, and other commodities. Typical applications include gathering and distribution systems, transmission lines and specialized pipe installations. Tens of thousands of kilometers of steel pipe have been joined using the Zap-Lok process under a wide range of operating conditions. Zap-Lok pipe joining machines have performed on virtually every type of terrain, under severe weather conditions and in hostile environments. They have been used to install portions of offshore pipeline systems and in joining both internally and externally coated pipe. The Zap-Lok method can be used to join thin wall pipe which cannot be easily welded; and due to the fact that no heat is required in the connection process a coated Zap-Lok joint can host corrosive fluid without the corrosive vulnerability of threaded couplings, or damaged internal coating resulting from high temperature produced by welding.
Like other steel pipe connection methods, and as per all relevant industry codes and practices, the Zap-Lok connection forms a joint that is ultimately stronger than the parent pipe itself under the pipeline operators designated loading conditions. This allows the pipeline system design to be based on 100% parent pipe strength. Extensive independent evaluations under varied laboratory test conditions and in-service performance records have proven the Zap-Lok joint to be strong, reliable and leakproof. Specifically, testing of axial tension and compression limits, pipe bending, and pressure limits indicate that Zap-Lok connections failed only at levels above those prescribed by the specified minimum yield strength (SMYS) of the parent steel. Furthermore, the Zap-Lok connection is fully compatible with inspection devices, including in-line, intelligent, smart, magnetic, ultrasonic pigging and hydrostatic inspection. Assuming proper installation and management, the Zap-Lok connection method is consistent with federal and state pipeline safety standards.
The Zap-Lok™ system enables significant advantages in construction speed and overall cost compared to other pipe-joining methods. The system replaces the variable performance, reliability, and cost of welders and other skilled labor with a highly efficient hydraulic Zap-Lok machine.
Every Zap-Lok joint is carefully prepared and inspected to ensure the highest connection integrity in the field. Our quality control procedures confirm that every heat of pipe meets both API dimensional tolerances and our own Zap-Lok specifications, thus reducing a large percentage of complications that commonly occur during construction.
The Zap-Lok™ system enables significant advantages in construction speed and overall cost compared to other pipe-joining methods. The system replaces the variable performance, reliability, and cost of welders and other skilled labor with a highly efficient hydraulic Zap-Lok machine.
Every Zap-Lok joint is carefully prepared and inspected to ensure the highest connection integrity in the field. Our quality control procedures confirm that every heat of pipe meets both API dimensional tolerances and our own Zap-Lok specifications, thus reducing a large percentage of complications that commonly occur during construction.
Zap-Lok is suitable for bare or internally coated pipelines, onshore and offshore, and in all terrain, climatic conditions, and configurations.
Benefits
- Oil and condensate takeaway.
- CO2 and water flowlines.
- Corrosive transmission and disposal pipe.
- High-pressure pipelines.
- Sour gas service.
Benefits
- Produces fully rated pipelines from 2 to 14 in., up to Schedule 80, X-65-grade (65,000 psi).
- Delivers permanent, high-strength connections.
- Minimizes in-field welding requirements.
- Consistent quality of each connection reduces risk.
- Exceeds production schedules with consistent construction rates of 800 to 1,000 ft/hr.
- Supports ASME B-31.4, B-31.3, and B-31.8 standards.
- Reduces manpower and infrastructure requirements.
- Cuts pipeline installation time and costs.
- Reduces HSE footprint- and welding-related risks.
Zap-Lok and Internal Coatings
Zap-Lok connections improve coating integrity while simplifying pipeline construction. By eliminating the heat of welding, Zap-Lok enables use of internal coatings without the risk of damage to the connection area.
Zap-Lok and External Coatings
When working in corrosive environments, extra care must be taken to prevent potential holidays from developing on the protective coating layer during traditional girth welding. By eliminating the welding requirements of exposed bare steel and high-heat, Zap-Lok connections allow a continuous holiday-free coating layer, free from a heat-affected weld zone.
For more information, please refer to https://www.nov.com/products/zaplok-pipeline-connection-system.
Zap-Lok connections improve coating integrity while simplifying pipeline construction. By eliminating the heat of welding, Zap-Lok enables use of internal coatings without the risk of damage to the connection area.
Zap-Lok and External Coatings
When working in corrosive environments, extra care must be taken to prevent potential holidays from developing on the protective coating layer during traditional girth welding. By eliminating the welding requirements of exposed bare steel and high-heat, Zap-Lok connections allow a continuous holiday-free coating layer, free from a heat-affected weld zone.
For more information, please refer to https://www.nov.com/products/zaplok-pipeline-connection-system.
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