The Challenge:
To conduct a full refurbishment, protective coating application and quality assurance testing for HSC pump casing. Ensuring enhanced corrosion resistance and structural integrity in accordance with strict industry standards.
Industry:
Power
The Solution:
Rebate of the split face and the suction discharge flanges of the pump housing was undertaken to ensure optimal mating surfaces to prevent leaks, maintaining precise alignments during assembly and improving structural strength for high-performance functionality.
An abrasive blasting on the internal surfaces was used to remove surface contaminants, rust, and old coatings, providing a clean substrate that promotes strong adhesion for subsequent coatings and protects against future corrosion.
This was followed by surface cleaning for residual dust removal. This involved a complete a final blowdown, sweep, and vacuuming to thorough removal of all dust and residual particles post-blasting. This ensures a pristine surface for coating application, free from contaminants that could impede the performance and longevity of the coating system.
Soluble salt testing was undertaken until an acceptable salt level was achieved. This reduces the risk of osmotic blistering and corrosion beneath the coating by ensuring minimal salt contamination on the surface.
Corroglass 600 Series was then applied internally to achieve (min DFT 1250 microns) to reduces the risk of osmotic blistering and corrosion beneath the coating by ensuring minimal salt contamination on the surface.
The wear ring landings were cast. Incorporating wear rings protects the internal structure from excessive erosion and wear.
Thickness measurements and a spark test at 17kV was taken after the coating had adequately cured. This ensures the coating thickness meets specification for optimal protection and verifies that the coating is defect-free. The surface protection was then removed and a 100% visual inspection undertaken.
An abrasive blast was undertaken (ISO 8501-1 to Sa2) to remove any residual contaminants prior to application of 2 coats of Plasmet ZF followed. This was followed by a Corrothane AP1 top coat to provide an additional protective layer against corrosion, extending the overall lifespan of the pump. The pump was then fully reassembled and pressure tested to ensure all components a were correctly fitted and operational under the required conditions.
This case study exemplifies a comprehensive approach to industrial equipment refurbishment, delivering a pump component capable of withstanding harsh operational demands while minimizing downtime and future maintenance.
Products Used:
