INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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Corroglass 600 and the engineering skills of our partner in Israel – Hamchadesh Industries – have returned a heavily corroded sea water pump impeller to its original profile and efficiency. Won in a competitive tender, the contract for Israel’s largest supplier of electrical power involved blast cleaning, welding to fill cavities caused by corrosion and machining the impeller to bring it back to its original dimensions after being coated with Corroglass 600 at 1500µm.
The client is delighted – the impeller has been reinstalled and is working at full efficiency again. A reduced need for maintenance in the future is also anticipated.
Black Point Power Station is located in the New Territories region of Hong Kong and is one of the world’s largest gas-fired combined-cycle power stations. Corrocoat Asia, based in Hong Kong, was contracted to inspect, repair and recoat the internal surfaces of eight auxiliary cooling water pipes which are used to convey seawater from pumps to a heat exchanger. The pipes were coated with Polyglass 100 when they were first installed in 1996 and have been in constant use since then.
The pipe internals were sweep blast cleaned to highlight areas where the coating had been damaged and a single coat of Polyglass 100 applied directly to the prepared surface, at 850µm. It is testimony to the excellent properties of the coating that only after 21 years of application was it found necessary to carry out repairs.
Corrocoat Caspian in Kazakstan has been certified to ISO 9001;2015 standard. This means that customers now have additional assurance that they are carrying out best practice in quality management and also demonstrates that the team is focused on continually improving its services to customers.
Kazakhstan is a fast-emerging market because of its importance as a leading petroleum, natural gas and minerals provider. Corrocoat Caspian manufactures and applies glass flake coatings from its facility at Almaty and has full capabilities to carry out site work at industrial sites throughout Kazakhstan.
A typical example was a contract to coat the internal surfaces of four 12m diameter cyanide tanks used to store alkali slurry at the Akbakai Gold Mine.
In a landmark decision IMO’s Marine Environment Protection Committee has ruled that from 2020, the sulphur limit on marine fuels must be reduced from 3.50% to 0.50%. This will have a major impact on the marine industry. Ship owners have several options to achieve this but undoubtedly the most economical solution is to install an approved SOx reduction method, for example a marine exhaust gas scrubber.
Our recommendation is that the scrubber exhaust gas outlet pipe be manufactured from highly anti-corrosive materials such as Super Duplex. However, these materials are very expensive and incorrectly specified when chlorides are present. Our licenced partner – Corrocoat Korea has been approached by several shipyards for advice and recommended the use of Polyglass VEF.
In a bid to use the lowest cost option some Korean shipyards investigated the use of Phenolic Epoxy but this is not suitable where sulphuric acid is present and within two or three years the coating would be in danger of breaking down.
In order to demonstrate the beneficial properties of Polyglass VEF, Corrocoat Korea has used the material at 1,500µm thickness on the internal surfaces of an exhaust gas outlet pipe at Hyundai Mipo Dockyard and is currently introducing the product to other shipyards.
The Industry – Power Generation
The Challenge – Corrocoat AS (Pty) Ltd was contracted by the South Africa Electricity Supply Commission to corrosion protect 2,216 Square metres of concrete trenches & sumps in the coal fired Wet Flue Gas Desulphurisation plant at Kusile Power Station. The plant is the first of its kind in South Africa for coal-fired power stations and allows it to conform to the Paris Agreement for environmental emission restrictions.
The Solution – The scope of works included the supply of all linings, primers, glass cloth, abrasive blast equipment and materials, airless application equipment, temporary structures and all site management and labour necessary to professionally deliver, install, QC test & warrant all site linings. The substrate was new cast concrete with a minimum 30Mpa strength.
All concrete surfaces were abrasive blast cleaned to remove laitance and then thoroughly vacuumed to remove dust and spent abrasive. All the surfaces were primed with Corrocoat WCP to wet-out the surface and seal any concrete pores. Multi-directional woven-roving glass-fibre, saturated with L600 Laminating Resin was then applied to increase structural stability and limit any potential for shrinkage during curing. Finally, a coating of Polyglass VEF to a DFT of 1000–1500µm was applied.
Results & Benefits – Thanks to the Corrocoat WCP/VE and Polyglass VEF coating system, which has a life expectancy well in excess of 20 years, the client now has a concrete floor that will require minimum maintenance.
Corrocoat USA Inc. was approached by a pulp and paper mill operator in Florida as the chime and foundation of its Tall Oil Caustic Tank were severely degraded, causing voids beneath the concrete slab. Affected by exposure to sodium hydroxide, sulphuric acid and black liquor, the concrete slab had low areas with deep puddles, further exacerbating the problem.
Having used a core drill and borescope to determine the location of sub-surface voids, cementitious grout was pumped into the voids. Corrocoat USA then re-directed all water or chemicals that would otherwise run onto the area into a nearby U Drain.
The concrete was washed with a pressure washer and organic degreaser, a containment built and the area blast cleaned. After sealing with Plasmet ECP, the concrete slab was regraded so that it would drain into the nearby sump. Finally, Polyglass VEF and Polyglass VE Veilcoat was applied to provide a surface that will protect the slab in this chemically corrosive service environment.
Larsen & Toubro Limited contracted KCPL to apply an internal lining to two new flue stacks at one of its power plants in Khandwa, Madhya Pradesh. Historically, all flue stacks in Indian power plants have been lined using borosilicate glass tiles or a titanium cladding. However, attracted by the significant economies of using a glass flake lining instead, the customer chose it, knowing both the track record of Corrocoat and the reliable service provided by KCPL.
The flues were 6m and 7m high and were coated on the ground. During erection, the joints were coated progressively in position. The contract involved: preparing the surface by abrasive blasting to ISO 8501-1 SA 2½ to achieve a surface profile of 50-75µm followed by the application of 800µm of Corrothane XT in a single coat to ensure corrosion protection from gases at around 240C. Independent tests that included the exposure to 300C for one hour were conducted prior to selecting the coating.
Although this is the first time KCPL had used Corrothane XT to treat flue stacks, the team had no hesitation in recommending it, firm in the knowledge that it has an excellent track record of successful use in similar extremely aggressive environments, worldwide.
Corrocoat is pleased to announce the launch of Fibrecoat– a vinyl ester lining containing both glassfibre and glassflake which will provide rehabilitation and a high-performance lining for thinned and corroded pipes and for where additional tensile properties are required.
Corrocoat Fibrecoat should be applied in single or multiple layers at up to 3000 µm per coat, with an airless spray pump of 45:1 ratio or greater, or for pipe internals a pipe sprayer. Normally used in Off-White or Translucent Brown, Fibrecoat has a spreading rate of 0.25m²/litre at 3,000µm.
Pipework and other equipment coated with the Fibrecoat will be corrosion protected and have greater structural strength, even after long periods – at a fraction of the cost and inconvenience of replacement. It is the ideal solution for capital process equipment where corrosion has reduced wall thickness to below an acceptable minimum.
Our Leeds Headquarters and the Thackray Medical Museum were the host venues last September for our International Knowledge Conference. Over 50 delegates from our global network of partners attended where a range of presentations provided a perfect platform to introduce new product developments and share information on developing markets and application successes.
After two days at Corrocoat, delegates moved to the Conference Suite at the Thackray Medical Museum. Here delegates also had time to enjoy the grounds and see the museum’s collection of over 50,000 objects from medical history which date from Roman times to the present day. There was also a full programme of social events including a conference dinner.
Over the course of the conference many presentations and practical demonstrations took place, from repair of compressors to pipe wrapping, sales management, concrete protection, the use of Fibrecoat and many more. This was a platform for our overseas operations to share their successes and experience with the group. All the presentations were very professional and extremely informative.
Our Belarus operation – LLC Corrocoat AKZ, has recently completed a contract to repair and corrosion protect leaking welds on a sour water tank for Mosenergo, the largest regional power generating company in Russia.
The customer was looking for a company who could: apply a coating system guaranteed to provide long-term protection and leakage protection; offer a turn-key solution and meet a tight time frame. As Corrocoat was the only company to meet these conditions, the contract was awarded to them.
The tank internal and manway were blast cleaned to ISO 8501-1 SA 2½. All corrosion pits were filled with Corroglass 602, 610 g/m2 multidirectional laminating cloth was applied to welds and corners, followed by a build coat of Polyglass VEF at dft of 600 µm. Finally, a second coat of Polyglass VEF was applied at total dft of 600 µm.
The customer was impressed with the quality of the finished job, and even though this was the first contract carried out for Mosenergo, Corrocoat AKZ immediately received a follow-on project to apply a coating to the inside surfaces of a hydrochloric acid storage tank.