Zap-Lok Pipeline Systems, Inc.
Typical applications include gathering and distribution systems, transmission lines and specialized pipe installations. Thousands of miles of 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 basic concept of the Zap-Lok process is relatively simple. A bell, or expanded area, is formed on one end of a joint of pipe, and a groove is formed on the opposite end. Both end-forming operations are accomplished with a hydraulic joining unit and a hydraulic groover, respectively, operated by hydraulic power units. These end preparations are automatically controlled to specifications required for the Zap-Lok joint. The belled end of one length of pipe and grooved end of another are forced together with a thin coating of Zapoxy serving as a lubricant. The resulting joint is a mechanical connection, with an Zapoxy "O" ring seal.
The Zap-Lok process produces strong, permanent joints which can be used in the same pressure service as welded lines. This allows the pipeline system design to be based on 100% joint 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. The Zap-Lok method can be used to join thin wall pipe which cannot be easily welded; and the Zap-Lok joint can carry corrosive fluid without the vulnerability of threaded couplings, or damaged internal coating resulting from high temperature produced by welding.
Pipe ends can be belled and grooved at the pipe mill, at the pipe yard, or at the job site and then joined by a hydraulic Zap-Lok unit in the field. Thin wall pipe can be joined by the Zap-Lok method in cases where welding would not be feasible. The Zap-Lok process requires less equipment and labor than needed with conventional welding work. It requires no special installation procedures or unusual auxiliary equipment. The Zap-Lok pipe joining unit is carried by a side boom tractor or mounted on a lay barge. Since only a brief training period is necessary, skilled craftsmen are not needed to operate the machine. Weather delays in construction are minimized because the process can be used in more extreme conditions then welding.
The Zap-Lok method of joining pipe complies with Section 192.273 of the United States Department of Transportation Pipeline Safety Standards, the requirements of ASME codes B31.4 and B31.8
The Zap-Lok method is recognized by several state regulatory and pipeline controlling bodies in the United States and Canada and thousands of miles of Zap-Lok pipelines have been installed in North America to the requirements of these regulators.