INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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Corrocoat Benelux was commissioned to apply a protective coating to five storage vessels on a newly constructed inland cargo vessel. The work was secured as Corrocoat Benelux had a proven track record, having completed similar work for the same client previously. Polyglass VEF had proved to be more resistant to the medium being carried – phosphoric acid 54% and sillicofluorohydroic acid – that the original material.
Due to construction delays the start date was pushed back by six months. Nonetheless Corrocoat Benelux remained flexible and through good planning were able to organise their workforce in line with client’s requirements.
Corrocoat’s team worked with Muehlhan who completed the grit blasting work employing their own ship which came alongside the vessel to be worked on. Polyglass VEF was specified at a thickness of 1000µm over the entire 2800m2 coated area. Tests showed that Corrocoat Benelux’s experienced sprayers achieved this without over-applying. They did an amazing job, staying within anticipated material usage.
The project was successfully completed and the storage vessels can expect an extended service life carrying industrial chemicals along the inland waterways of Holland and the low countries.
A petroleum client in Kuwait deemed one of their impellers “unrepairable” due to corrosion from salt water, and an accelerated rate of corrosion as a result of extreme hot weather – Kuwait is recorded as one of the hottest countries in the world, with temperatures averaging as high as 54°C. The instruction was given for our Kuwaiti partners, Al-Sabaiea National, to “completely replace it with a new impeller” as the equipment specialist stated it was unrepairable and would not be able to function properly.
With the application of Corrocoat’s Polyglass series, the Corrocoat team were able to refurbish and restore the impeller back to a working condition, despite testing weather conditions, which made it extremely difficult for the team to work in the exhausting heat and humidity.
When presented to the client the impeller was unrecognizable, almost like new. Needless to say the client was extremely impressed with the ability of Al-Sabaiea National, and the product used to repair the impeller from the condition it was in previously. They were also very impressed with the costs saved from having to buy a completely new impeller and the fact that the repaired and freshly coated impeller would outlast the service life of a brand new one.
A leading producer of energy and chemicals in Saudi Arabia recently put out a tendering contract for corrosion protection on a number of components and ongoing work. The company pride themselves on being part of the global effort towards building a low carbon economy. Our Saudi Arabian licensees, Altrad, won the contract and are now working with the company on a number of different projects over a period of two years.
As part of the series of initial projects, a number of pipespools required repair and restoration from corrosion damage at a seawater injection plant. The project ran over 9 months and Polyglass VEF was the primary coating system used throughout. Polyglass VEF was the ideal coating system for this project, protecting the spools from future corrosion damage from seawater and in turn extending their service life considerably.
The sole transmission and distribution system owner and operator for the electricity and water sector in Qatar, recently required internal corrosion protection on a potable split case pump, which had been in operation for several years.
Upon inspection by Alhuda Corrosion Treatments (our partners in Qatar), substantial corrosion was found on the internal pump body, alongside general pitting and metal erosion. In order to repair and extend the life of the pump, Alhuda Corrosion started by abrasive blasting the internal pump surface. Chloride testing was conducted before and after the blasting process to ensure that the salt water levels met the required low specification in the substrate, ahead of application.
Corroglass Lamination Resin 600 and multi axial fibre cloth was applied on the pitted and eroded areas, reconstructing and restoring them back to the original size and shape. Upon completion of the lamination process, Polyglass VEF was applied by air less spray to 1000 micron, on the internal surface of the pump. Polyglass VEF is suitable for many chemical environments within the full pH range. A quality control thickness check was carried out to ensure compliance to the written specification, and coating integrity was assured by a high voltage holiday test.
Polyglass VEF will protect the cast iron substrate and offer good resistance to abrasion for many years, considerably extending the service life of the pump.
Kirloskar Corrocoat has become the only Indian company to successfully coat the internal surface of a steel chimney stack, standing at an enormous height of 130m. The chimney stack, located at a major refinery in Northern India, was repaired in situ during a scheduled shutdown at the refinery, within a specified timeline of just 28 days.
This full turnkey project required a suspended winch platform to enable the coating team to manoeuver up and down the chimney internal, whilst carrying out the required work. The team cleaned the internals with high-pressure water jetting, to remove the dust inside. The project was completed during the winter months, with temperatures ranging from 5-15°C and foggy throughout. Dehumidifiers were used to control the environment during the application.
The chimney would be operating without flue gas desulfurization for a few years, at a temperature in the range of 135-150°C and it was confirmed by the client that if the preheater failed, the temperature could rise as high as 300°C for between 15 to 30 minutes. With this in mind, Corrothane XT was the coating system selected for this project. This three-pack cold cured vinyl ester urethane polymer alloy with high performing glass flake is an ideal choice for coating both steel and concrete surfaces, where good chemical and high temperature resistance is required. The coating was manufactured and supplied directly by Kirloskar Corrocoat.
Despite extremely tight timescales and undesirable cold and foggy weather conditions, the project management team along with internal and external stakeholders were able to complete this project on schedule and to exacting standards.
Corrocoat Fibrecoat is a glass fibre reinforced vinyl ester glass-flake coating, developed for use as a high performance lining and rehabilitation material for thinned/corroded pipes, and where additional properties are required.
Designed to be applied by Corrocoat Agmec Airless spray equipment, recent modification to the Agmec small bore pipe sprayer, now allows the material to be successfully applied in pipe diameters down to only 150mm in diameter.
Trials also showed that small holes can be successfully covered and sealed using only two coats of Fibrecoat.
The new equipment will allow smaller bore pipework to be fully refurbished without the need for expensive excavation and disassembly, generating significant savings in cost and time.
The product has great structural properties, and for a severely damaged pipe, Fibrecoat will create a pipe within a pipe.
System Benefits:
India’s largest EPC (energy, procurement and construction) conglomerate constructed a massive ship lift facility in Southern India, capable of lifting a ship of 200m length with a width of up to 43m. Essentially the ship lift is an enormous elevator used to raise ships out of the water to enable dry-dock onshore maintenance work to be completed. The continuous lifting and lowering means the ship lift platforms are continuously in the splash zone, and at risk of corrosion due to continued wetting with salt water combined with exposure to oxygen rich air.
Originally coated in 2011 by an different company, after six years’ service it was evident that recoating work was required. The job would require a host of technical and site management skills, and KCPL Corrocoat, out partners in India, were successful in securing the contract.
After some test procedures had been carried out, it was decided that vapour blasting was the best solution to adequately prepare the lift surfaces for coating and Polyglass Zipcoat was applied to achieve a DFT of 1000μm. Polyglass Zipcoat provides durable corrosion protection in aggressive atmospheric conditions and immersion environments. In total, around 1500m2 was blasted and coated throughout the project, and the team were very proud to complete the work on time.
The feedback from the client was extremely positive and the coating is performing as required in this testing splash zone environment, so much so that the client renewed the annual rate contract for another year.
Over the past two years, Corrocoat Indonesia has been working at two coal fired power stations located in Pacitan City in east Java. Both 315 megawatt (mw) power stations required work on the inlet/outlet tube sheet condensers, which were suffering from leaks on the welded joints of the titanium tubes. This damage was affecting the efficiency of the heat transfer and allowing steam to escape.
Corrocoat Indonesia recommended coating the affected tubes – a total surface area of 120m2 – with Plasmet HTE at 1000-1500μm DFT. HTE contains stainless steel flakes, glass flakes and silicon carbide, making it the ideal choice for areas requiring abrasion resistance.
The projects were completed over a period of 30 days, during which other jobs were completed including lining a vertical lift circulating water pump and an oil tank.
The successful completion of the works created a great deal of awareness in the industry especially with other coal fired power station operators. This raised profile resulted in Corrocoat Indonesia being contracted to complete a similar job at another coal fired power station in Java and it is anticipated that another contract at a 4,025 mw coal-fired power complex in Banten Province, Indonesia, will happen as a result.
Al Huda Corrosion Treatment, our partners in Qatar, took delivery of a severely damaged sea water pump in need of complete refurbishment and a protective lining. Al Huda’s client; a specialist pump company described the pump as having severe corrosion and erosion damage and metal loss, all of which needed to be addressed.
Abrasive blast cleaning revealed the true extent of the damage and Al Huda’s technicians used Corrofill E and Plasmet HTE at a DFT of 1200μm to repair and line the pump internals. The external required a combination of weld repairs, composite lamination to add strength and Corrofill E before a final top coat of Plasmet ZF was applied to offer all round protection.
The shaft was cleaned and reinstalled in the pump along with a new impeller and new mechanical seals, before a pressure test to 1.5 times its service operating pressure to ensure the quality of the work completed.
The client was extremely pleased with the quality of workmanship as well as the significant cost saving achieved when compared to purchasing a new pump.
Did you know Corroserve’s dedicated pump division offers customers a comprehensive service covering refurbishment, re-manufacture, modification, coating and improved efficiency to many types of pumps? Find out more about the pump repair and pump servicing and monitoring services we offer here.
Corrocoat Caspian was asked by Tengizchevroil – a Chevron subsidiary, to internally line four 10,000m3 tanks used to hold river water required in the production process. Tengizchevroil operates the huge Tengiz oilfield in western Kazakhstan.
Strict time constraints meant the work needed to be completed quickly. In order to achieve this, Corrocoat Caspian used two teams of 14 people working on both day and night shifts. In total, an area of approximately 16,000m2 was coated with Corrocoat ZIP E. This material is an epoxy glassflake coating, intended for a single coat application and was specified for this project because of its excellent application characteristics and durable single coat protection in aggressive atmospheric conditions.
The work was completed one month ahead of schedule, needless to say Tengizchevroil were extremely impressed with the quality of the work and of course the early completion date.
We are proud, along with our international partners, to work with many multi-national oil and gas companies, providing advanced glassflake linings and a range of products and services for their pipes, pumps, vessels and tanks.
