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Exhaust Stacks External Corrosion

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Exhaust Stacks External Corrosion

Industry:                          

Co-generation & Gas

 

Date:

November 2010

 

Substrate:

Mild Steel

 

Products:

Epo-chem™ RL 500PF – Surface and moisture tolerant zinc rich epoxy

 

Environment:                  

Methane gas co-generation plant exhaust stack trials.

 

Challenge:

15 year old plant was showing signs of premature corrosion within 3-4 years of commissioning. Spark free surface preparation was a strict requirement. Plant outage was not possible and work was required to proceed whilst online with an estimated 105°C on the surface.

 

Methane Gas Power Plant
Methane Gas Power Plant
Corroded exhaust pipes and manifolds
Corroded exhaust pipes and manifolds
Extent of surface corrosion
Extent of surface corrosion
Exhaust stacks after 5 years in service
Exhaust stacks after 5 years in service

 

Chemco’s Solution:

Chemco’s application of wet & surface tolerant coatings was carried out with minimal disruption to the everyday activities with an expected life in excess of 10 years before any signs of corrosion are visible.

 

Scope:                       

Mobilize to site and work in with plant maintenance personnel to ensure all risks are assessed and reduced where possible. Obtain safe access and mechanically clean, using a wire brush only. Application of 2 coats of RL 500PF with a nominal DFT of 300µm.

 

Results:

Many other coatings were trialled and failed within a 3 month period. The site has been revisited many times over the past 5 years with no signs of coating failure. Plant Maintenance Engineers are pleased with the results and look forward to solving other corrosion issues.

 

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