OVERVIEW: Chemcote has a 14 year ongoing relationship with this customer to perform maintenance and overhaul work. Regular inspections allow us to document the status of the assets and make recommendations about further servicing. This continual monitoring and timely application of protection has successfully reduced long term maintenance costs for our customer. The case notes below describe the latest co-ordinated overhaul carried out in 2020.
INDUSTRY
ENVIRONMENT
Wet blast furnace gas, from 20-40°C
SUBSTRATE
Steel outlet and inlet spools, flange faces, shut off valves, turbine casing components and manway covers
CHALLENGE
The overhaul was coordinated and planned for the completion of some components in Chemcote’s workshop
On-site work was carried out by setting up appropriate containment and navigating difficult to access areas to achieve thorough cleaning and surface preparation
SOLUTION
Apply Chem-tect RB 364 series to the internals of the pipework and casings in 2 coats where possible
This glassflake filled vinyl ester has proven to be most suitable for applications where good corrosion resistance and excellent mechanical properties are required
SCOPE
Full treatment where required;
Pressure wash, abrasive blast internals and externals
Full abrasive blasting was carried out on internals on-site for full refurbishment
Seal redundant holes and split rings using polyurethane
mechanical preparation and small touch-up repair
PRODUCTS
Chem-tect™ RB 364 to coat internals
Epo-Chem™ RW 500 for spot repairs
Reinforcement using Kevlar
Spot repairs using Ind-Cote on struts
OUTCOME
Chemcote has successfully reduced long term maintenance costs by carrying out intermittent inspections and documenting recommendations for coating systems used over the 14 year service duty
RELATED CASE STUDIES
Refurbishment of Basket Strainer
Strainer nearing completion Internals nearing completion Internals illustrating pit filling After abrasive blasting, pitting After fabrication repairs OVERVIEW: Chemcote provided a long term corrosion protection for
Preventing blockages using Chemcote Solution
Condition of surface before mechanical preparation RB 364 applied to spot abrasive blasted surfaces Pugmill externals Coating with InD Cote Previous Next OVERVIEW: A
Base Plate Corrosion Prevention
Repairs required Application of Primer Coating applied to affected areas After application of Topcoat Previous Next OVERVIEW: A 40 year old excess gas bleeder structure
OVERVIEW: Chemcote’s specialist team mobilised to site to deliver a multiple layer protective coating system that would return the asset to working condition within 24 hours. Abrasion resistant coatings were applied to the pugmill and paddles over a 12 hour period during plant shutdown, with 12 hours allocated for curing.
INDUSTRY
ENVIRONMENT
50-70°C 10-40μm abrasive particles from the dust catcher are disposed of in the pugmill and combined with water to suppress the dust creating an abrasive sludge
SUBSTRATE
Steel Substrate
CHALLENGE
Deliver an operational multi coat abrasion resistant coating system within 24 hours
SOLUTION
Thorough surface preparation prior to the application of multiple layers of abrasion resistant coatings. Spot abrasive blasting to minimise disruption to surrounding trades.
SCOPE
Pugmill Internals
Spot abrasive blast localised areas.
Apply of 1 coat of fast curing Chem-tect™ RB 364C to areas where required
Use chopped strands and where deep pitting existed to provide a smooth even profile
Apply 2 coats of Chem-tect™ RB 364CS to 1,000μm
Conduct QA, DFT and high voltage spark test to ensure continuity at required voltage
Paddles
Abrasive blast to AS 1627.4, Class 2.5 with a minimum 75μm profile.
Apply 1 coat of Epo-chem™ RW 500 to a nominal thickness of 500μm to ensure no transparent areas
Complete casting application 1 coat of InD-cote™ to 6000 micron DFT to the load and back faces
PRODUCTS
Paddles coated using Epo-chem™ RW 500 and InD-cote™
Pugmill Internals Chem-tect™ RB 364CS
OUTCOME
Chemcote’s solution has extended the life of this asset by 12-24 months, and delivered a 30% improvement in functioning. Continuous high performance is guaranteed until our review at the next planned outage.
RELATED CASE STUDIES
Refurbishment of Basket Strainer
Strainer nearing completion Internals nearing completion Internals illustrating pit filling After abrasive blasting, pitting After fabrication repairs OVERVIEW: Chemcote provided a long term corrosion protection for
Preventing blockages using Chemcote Solution
Condition of surface before mechanical preparation RB 364 applied to spot abrasive blasted surfaces Pugmill externals Coating with InD Cote Previous Next OVERVIEW: A
Base Plate Corrosion Prevention
Repairs required Application of Primer Coating applied to affected areas After application of Topcoat Previous Next OVERVIEW: A 40 year old excess gas bleeder structure
