INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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The Shuaiba industrial Area accommodates many of the large-scale industries in the State of Kuwait. over 30 processing plants are located here, including petrochemical companies, oil refineries, power plants and gas companies. there is a huge demand for sea water for cooling purposes and the Kuwait public Authority for industry is currently investing in a power plant renovation programme to ensure that the demand for cooling water is met in the future.
The contract to re-line Shuaiba Plant B header cooling water pipes was awarded to Corrocoat Distributor and Applicator in Kuwait, the Al-Sabaiea Group thanks to its excellent track record of successfully completed coating projects for major operators in the oil, gas, and support industries.
Two 2.2m ductile header pipes each 180m long were re-lined. Following full surface preparation the following Corrocoat products were applied. Polyglass VE to fill and repair pitting, PPA primer to hold the prepared surface and finally P100 in two coats to achieve an average film thickness of 1250 μm. Armagel was used on header bends to resist against erosion and abrasion issues.
Corrocoat USA has solved a very costly problem for one of the country’s oldest pellet mills in South Georgia. An ongoing problem for the mill has been the need to constantly repair damage at the impact zone of a 56” diameter x 19’6”long exhaust elbow. Despite trying a number of different types of coating and/or rubber combinations, repairs, including patches have been necessary every three months.
The solution provided by Corrocoat USA was to: weld patches to the damaged areas; abrasive blast to a profile of 50-100 microns, apply Plasmet HTE to 1500 microns. Calcined alumina tiles with a Plasmet HTE grout were then applied followed by a final coat of HTE to finish the tiles.
After several months continuous use, the lining remains in a good condition and the operators of the pellet mill are very satisfied with the huge savings which have resulted from the Corrocoat solution.
Gas desulphurisation plants have been in use for over 35 years but the wet scrubbing process results in highly corrosive conditions in plant and flue gas ducting. the problem is made worse as a number of different aggressive corrosion conditions occur and therefore several protection products and application skills are required. We have developed a number of products to provide long-term corrosion protection in gas plants and over the years Corrocoat Benelux have used these on a number of contracts.
For Waste Management and Renewable Energy Companies -HVC in Dordrecht and AVR Rotterdam, large flues from waste burning plant have been protected with Polyglass VEF, a glass flake vinyl ester acrylic co-polymer which offers high levels of resistance in chemical environments within the full pH range.
At a sludge treatment facility operated by SNB in Holland, and industrial gas manufacturer, Air Liquide in France, Corrothane XT has been used on flue duct protection contracts. This cold cured vinyl ester hybrid was developed for coating steel where, as in these cases, high working temperatures are experienced.
All these installations are audited regularly and time has proved that Corrocoat products continue to provide the required protection and will do so for many years to come.
Licensed applicator, Vietnam GloCoating Engineering JSC (VGCE) was contacted by PetroVietnam Ca Mau Fertilizer JSC, as their engineers were concerned over the condition of one of their pumps. The pump is used in the production of nitrogenous fertilizers and was handling abrasive and corrosive chemicals.
VGCE engineers recommended a coating system that would protect the pump casing and impellor comprising:
All surfaces to be shot blasted to remove contaminants and achieve a surface profile of 75 µm. to allow the subsequent coatings to bond successfully and guarantee their longevity.
For the pump internals and impellor a coat of Corroglass 632, followed by Corrofil VE (to fill holes), Corroglass 602 and finally Corroglass 652 applied to achieve a total thickness of 1800 µm. This coating combination was recommended as it combined excellent abrasion and corrosion resistance and was therefore an effective and long term solution.
The pump casing external surfaces to be coated with Plasmet ZF at 250 µm, the pump housing flange faces rebated and the impellor balanced.
The contract was awarded to VGCE and the work carried out in its own workshops. The customer was delighted with the end result, marking the Work Completion Report – Good for both Service and HSE performance.
As the name would suggest, Mangalore Chemicals and Fertilizers in the state of Karnataka, India manufactures fertilizers, potash and other products which are used by farmers across southern India.
Many of the products are highly corrosive and this, combined with a saline atmosphere encourages severe corrosive conditions and as a result key parts of the plant have to be fully protected to keep them operating at maximum efficiency and to prevent premature failure and product contamination.
As part of the plant’s maintenance programme Kirloskar Corrocoat Private Ltd (KCPL) were selected to apply a protective coating system to the plant’s conveyor steelwork. Selecting the best system is critical to ensure the extended life of the conveyor structure, so KCPL engineers recommended the application of a single coat of Plasmet ZF at 175 µm followed by a final coat of Plasmet ZE at 275 µm to achieve a final DFT of 450 µm. This combination would ensure that the finished coating would be durable, chemical and abrasion resistant and provide effective long-term protection.
The work was carried out during a planned maintenance shut down and was completed safely, on schedule and within budget.
One of our latest licensed partners – CorroTech in the Czech Republic is winning contracts in a variety of markets – their expertise and proven Corrocoat products proving to be deciding factors in clinching orders. Here are two recent examples.
REFURBISHMENT OF HYDROGEN COOLING SYSTEM
Operating an electric power generator produces large amounts of heat that must be removed to maintain efficiency. The use of hydrogen is an effective way to cool the generator and allow power plant operators to produce more megawatts out of a smaller generator.
The problem is, hydrogen can be dangerous so to ensure maximum safety and equipment efficiency regular maintenance of all components is vital. As part of a planned maintenance programme CorroTech were contracted to refurbish the hydrogen cooling coils.
Carrying out the work in its own workshops, the coils were first degreased, then high pressure water hosed, before being blast cleaned to standard Sa 2½ with a sharp-edged surface profile corresponding to Rugotest No. 3,BN9a. The external surfaces, some 15002m in all, were then coated with Polyglass VE to a dft of 1500 µm. Polyglass VE – a two-pack, cold cured epoxy vinyl ester material is ideal for this application, offering high resistance to chemical attack at the elevated temperatures found in a cooling tank.
STERLISATION TANKS
CorroTech has also successfully completed the anti-corrosion coating of 10 sterilisation tanks. Following degreasing, high pressure water hosing, and blast cleaning to Sa 2½ standard, two coats of Corrothane XT were applied to produce a dft of 1200 µm. In all some 250m2 was coated. Pioneered by our expertise in glass flake manufacturing, Corrothane XT is a three-pack cold cured epoxy vinyl ester urethane material which can be used on a wide range of substrates in both immersed and non-immersed service.
India’s biggest private sector steel company – JSW Steel Ltd., operates several manufacturing plants in India and is a world leader in the supply of steel for the automotive, construction and energy markets.
The successful completion of a similar contract at JSW Steel’s Vijayanagar works in Bellary, resulted in Kirloskar Corrocoat Private Ltd (KCPL) securing an order to clean and corrosion protect the internal steelwork of a blast furnace stove dome at the company’s Dolvis steel manufacturing plant.
The stove dome, which holds the gases used to heat a blast furnace is 10m diameter by 45m long – in all a total of 1800m2 was airless sprayed using Polyglass VEF and for smaller areas where spraying was impractical, VEHA was used – applied by brush. Polyglass VEF/VEHA offer excellent corrosion, chemical and temperature resistance.
“Satisfied customers placing repeat orders are testament to the quality of Corrocoat products and the professionalism of our service” says KCPL’s Chief Executive – Jackie Dias. “As an existing customer, JSW Steel is well aware of the advantages of using our services, and has chosen KCPL as a preferred provider of anti-corrosion services.”
Following a series of independent tests, Corrocoat Zip-E has been approved to UK Defence Standard 80-97 – Internal Coating of Aviation Fuel Tanks.
The installation of a coating system is an effective way of protecting steel fuel tanks from corrosion and product contamination, minimising the risk of corrosion products getting into aviation fuel. Any coating used must not degrade the performance of the fuel which it is in contact with, nor must the fuel degrade the coating. Corrocoat Zip-E fulfils this brief providing durable protection. Achieving Standard 80-97 is a key milestone in our plan to increase our aerospace customer base.
Corrocoat Benelux has recently completed a contract for a leading automotive manufacturing company to clean and protect the internal surfaces of an electro-deposition (ED) coating tank to extend its working life.
Using a combination of dip and spray, ED coating plants are used throughout the automotive industry. In these plants, electrically charged paint pigments reach every corner of even the most complex fabrication. Un-deposited material is then washed away and after stoving the final coating becomes hard and durable.
The tank must be kept in a very clean condition, free from anything that could affect the quality of the finished component. After submitting a highly competitive tender, Corrocoat Benelux was contracted to carry out the tank cleaning and coating using Corrocoat materials approved by leading ED coating suppliers.
This involved blast cleaning all surfaces to standard SA 2 ½ before applying Polyglass PPA primer, followed by two coats of Polyglass VEF. Once cured the coating thickness was spark tested to ensure a pin-hole free minimum thickness of 1500 µm before a topcoat of VE Veilcoat applied.
As with many automotive production plants, disruption to production had to be kept to a minimum so the work was scheduled to be completed in a planned outage.
Kirloskar Corrocoat Private Ltd (KCPL) – our joint venture in India, recently hosted a seminar in Puna around the theme: Extending the life of capital equipment in the sugar industry with high performance coatings and the latest refurbishment technology.
Over 100 delegates from the Indian sugar industry attended the seminar and over several sessions, delegates were given the opportunity to learn how KCPL solutions could provide savings in plant maintenance costs, reduce energy costs and improve production efficiency and how best to use Corrocoat products within their organisations for maximum benefit.
The seminar was a huge success and KCPL are now planning more seminars aimed at other key markets.