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Oil Cooler Water Boxes

OVERVIEW:    Deep pitting was found in many areas of the 35 year old oil cooler water box requiring pit filling and reinforcement using composites. Water boxes needed to be coated on site with minimal disruption to adjacent turbine hall.

Our solvent-free epoxy glass-flake filled coating has excellent resistance to the 60°C Salt Water environment.

INDUSTRY

ENVIRONMENT

60°C Salt Water Immersed

SUBSTRATE

Cast Iron

CHALLENGE

To refurbish and extend the operating life of extensively corroded, 35 year old, oil cooler water box.

Deep pitting was found in many areas requiring pit filling and reinforcement using composites. Water boxes needed to be coated on site with minimal disruption to adjacent turbine hall.

Prepare, coat, cure and complete in a duration of four days.

SOLUTION

We recommended coating with RA 532, a solvent-free epoxy glass-flake filled coating, which has excellent resistance to this particular environment

SCOPE

Water Boxes – Onsite

Needle gun difficult to access areas

Remove graphitised materials with high pressure water blast at 20,000psi

Assess damage and apply one coat of RS 500P integrated with a fibreglass matting to cope with low pressure

Application of two coats of RA 532

Conduct QA, DFT and high voltage spark test to ensure continuity at required voltage

Covers – Workshop

Abrasive blast to AS1627.4 Sa2.5 with a nominal surface profile of 75µm

Hot wash to reduce presence of metallic salts to <25ppm and re-abrasive blast

Application of RB 332

OUTCOME

The first unit was coated in 2006 with an expected operating life of two years due to plant redundancy. This unit has continued to remain online and in great condition for a substrate that is more than 60 years old. It is expected to last another ten years.

The newly coated water boxes were completed without incurring costs for abrasive blasting, encapsulation and were carried out with reduced downtime.

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