INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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Our partners at Corrocoat Benelux, recently worked on a project to repair a secondary settling tank, which was suffering from severe corrosion. The tank, which had its last inspection over 10 years ago, had been in service at a petrochemical plant, and was in much need of repair, having been subjected to waste sludge.
Following an on-site inspection, during an outage, it was discovered that the 2 outer shells, which were 2.4 metres high, with a diameter spanning 4.5 metres, were severely corroded.
Before transportation to the Corrocoat workshop, the skirt of the tank was dismantled by the Corrocoat team, to allow for easier transportation and repair. Upon arrival, the shells were abrasive blasted, before Corroglass 632 was applied to prime the substrate. Fibre glass matting was then applied to the damaged areas, ahead of 2 layers of Polyglass VEF.
The client was extremely impressed with the finished result, and the team are confident the protective coating would exceed a further 10 years in service.
Find out more about how we can repair and protect tanks with our protective coatings here.
One of the largest and most competitive engineering, procurement, construction and installation contractors of offshore oil and gas projects in the Asia-Pacific region, recently approached our partners in China, to provide leakage prevention for an open drain caisson.
With leakages being a very common problem with this type of equipment, the client had considered repairing the issue as and when it would happen, using diving and injection repair. This approach is fairly common, but is expensive and may cause environmental consequences, with leakage of hazardous material to the sea.
The client decided providing leakage prevention for the open drain caisson; protecting the 52-metre long piece of equipment, and extending its service life form the start, with Corrocoat, was the best and most viable option. As part of the project the client commissioned the team to also protect the internals of an attachment pipeline, which was to be inserted in the caisson.
The team completed the project on-site and selected Polyglass VEF to line the caisson internals, via spray application. The pipe internals were also coated with Polyglass VEF, after first being split in to 2 sections. Once cured, the client welded the pipe sections back together, and a total of 10 pipes were inserted in to the caisson.
When in position, the team re-prepared the field fit weld area and coated over the weld joints with Polyglass VEF to complete the corrosion protection. The conditions in the caisson to complete the final stages of the project were very challenging, with a restrictive workspace as a result of the diameter of the caisson and the inserted pipes.
We recently welcomed Superintendent, Ryan Robertson (Corrocoat USA), Development Manager, Nguyen Minh Hieu and Tran Quang Phuc, Commercial and Services Department Manager (both from Vietnam Gre-Coating Engineering Services JSC), to the Corrocoat UK Head office. The trio were trained in our Composite Structural Rehabilitation System; which uses a combination of specialised laminating resins, interlayered with glass reinforced polymers (GRP) composite laminates to give structural strength to corrosion damaged pipework, and other damaged plant and machinery.
Whilst visiting the UK Head Office, the trio embarked on a full and comprehensive 2 weeks of training. Overseen by our Technical Services Engineer, Douglas Lynch, their visit started with advanced theory-based training, offering a deeper insight in to corrosion, service environments, product specifications and more. They then moved on to practical training, working on a number of projects in the coating and engineering workshop, overseen by Douglas and guided by Engineering Supervisor, Warren Marks – who has been part of the team here at Corrocoat, for almost 30 years.
From disassembling and working on the refurbishment of a large valve, to pipe casting, specialist coating techniques; including spraying and flood and drain, the delegates worked on a number of projects with our expert in-house team.
Douglas also took Ryan, Hieu and Phuc through their Composite Structural Rehabilitation (CSR) training, whilst Engineering Manager, Simon Cappleman carried out specialist pump training and showcased the intricacies of our in-house pump division and specialist proprietary Agmec Pipe spraying equipment.
The visit concluded with Ryan, Hieu and Phuc being presented with their certificates upon successful completion of their training.
Douglas said; “It was a pleasure training Ryan, Hieu and Phuc and I wish them continued success in their roles. I look forward to staying in touch with them and being updated on how their training at head office enhances them in their roles, and they pass on their knowledge to benefit our operations overseas.”
India is the not only the largest consumer of sugar in the world, it is now also the largest producer of sugar, displacing Brazil. The Indian sugar industry is the second largest agro-based industry in India.* With this in mind, our partners in India, Kirloskar Corrocoat, regularly work with clients in the sugar industry, providing refurbishment, repair and corrosion protection for plants and ancillary equipment. Kirloskar Corrocoat have applied Fluiglide E to more than 500 pumps in the sugar industry: providing improved efficiency, along with corrosion protection to considerably extend the life of the pumps.
Fluiglide was featured in the product showcase in the last edition of Corrocoat News (the May 2022 issue). These energy-efficient products maximise the performance of pumping systems used in power generation cooling water systems, water & waste treatment and process industries worldwide. They also provide an effective corrosion barrier, preventing early fall-off in performance due to nodular growth, corrosion and surface roughness.
Kirloskar Corrocoat recently worked with a client/sugar factory in the populous state of Maharashtra. They took on a project to refurbish and protect 5 injection water pumps (ranging from 6” to 16”) with Fluiglide E, with the aim of improving overall efficiency.
The below images show the top and bottom casing and the impeller.
Note, the wear ring portions and bore ID area were totally damaged by erosion & corrosion. The hydraulic portion of casing was in a heavily damaged condition.
For the refurbishment work, the internals were grit blasted in accordance with ISO-8501 to Sa2 ½ surface finish, and then coated using Fluiglide E, applied by brush to a minimum DFT of 1.2mm. The pitting and cavities were filled with Corrocoat EA; a viscous, solvent-free, high build, two pack epoxy coating with excellent erosion resistance, toughness and outstanding anti-corrosive properties. The internals were then spark tested at 10kV.
The externals were also grit blasted to Sa2 ½ surface finish and coated with a standard epoxy paint for aesthetic effect only, as requested by the client. Bearings and wearing rings were replaced, and the pumps were then reassembled using new fasteners, gaskets and fixings.
Assembled pumps awaiting dispatch to the client.
Find out more about how our coatings and services can repair and protect your pump and help improve efficiency, here.
Fibrecoat is a glass fibre reinforced vinyl ester glass-flake coating. Developed by Corrocoat, for use as a high-performance lining, Fibrecoat rehabilitates severely corrosion damaged pipes, and adds exceptional mechanical strength. The coating may be applied in a single layer or multiple layers at up to 3000 microns per coat. This hold-up capability makes the coating excellent at filling through-wall defects and bridging cracks, which ultimately leads to creating a composite pipe within a pipe.
Fibrecoat is highly abrasion resistant and suitable for application in aggressive service conditions, making it ideally suited to sewage applications. The coating system also has high temperature resistance. It is applied using the our specially designed airless spray equipment, the Agmec Pipe Sprayer, and we recently used the pipe spraying equipment to demonstrate the application of Fibrecoat to a 6” nominal bore pipe, which was 5.3 metres in length.
The pipe sprayer is used to coat pipe internals with suitable coatings. The coatings are atomised by centrifugal force that is produced by the specially designed spray cup. An oscillating spray pattern is produced through the spray cup being angled to the rotating head, so as the head turns, a to-and-fro movement is generated, much as would occur with a hand application.
The Agmec Pipe Sprayer allows for long pipe runs of up to 100m in length, and from 150mm to 1.2m in diameter to be coated in one pass. Savings are significant and in many cases pipework can be blasted and coated in-situ, without the need for expensive excavation and disassembly.
We prepared a sample 6” nominal bore pipe, which had suffered from corrosion damage, for the demonstration. The pipe had a set of holes drilled in from 6mm to 25mm, which were positioned at 12 o’clock and 3 o’clock. These were in place to demonstrate the coatings hole bridging properties, after applying a single coat and multiple coats.
For this application, the pipe was abrasive blasted. As Fibrecoat can be used to provide a composite pipe within a pipe, providing high hoop strength, a low-level surface preparation for application is possible in some environments.
An airless spray pump was connected to the pipe sprayer, with appropriate hoses for the diameter and length of the pipe. Following cleaning and flushing, the pump was then primed with a small amount of a lower viscosity, chemically compatible Corrocoat coating to aid the initial pumping of Fibrecoat.
The sprayer was deployed to the end of the pipe by pulling through with a previously fed small line. It was stopped at the end of the pipe with the sprayer head protruding.
The coating was atomised by centrifugal force that is produced by the specially designed spray cup. A fan angle spray pattern was produced through the spray cup being angled to the rotating head.
The coating covers hole sizes up to 12mm in a single coat and up to 25mm in two coats, depending on the DFT achieved.
Following cure, further coats can be applied to the desired thickness and to complete the bridging or filling of defects. Click here to see the full demonstration.
Corrocoat have been successfully applying coatings to pipes for decades. The development of Fibrecoat adds another dimension to our already vast range of pipe protecting capabilities.
For more information on Fibrecoat and/or the Agmec Pipe Spraying equipment, contact a member of the team here.
Our partners at Corrocoat Benelux were recently commissioned to coat 300 square meters of new flue gas duct sections, with a diameter of 2200mm. The sections were intended for an energy from waste plant and required a coating which could protect the steel against flue gases. Corrocoat Benelux have a long standing relationship with the client, who specialise in fabrication of this type of equipment, and have worked with them on numerous projects over the last 10 years.
The project was carried out at the Corrocoat workshop, and took a team of 4 men, under 2 weeks to complete. The sections were blasted internally and externally to Sa2 ½. A surface profile of approximately 70 microns was achieved on the internals, which was then coated with Polyglass VEF using airless spray application. Polyglass VEF is a glass flake vinyl ester acrylic co-polymer, which has superior resistance to chemical attack and high temperature resistance. The externals were coated with 1 layer of Plasmet ZF which once again offered superior resistance in a chemical environment.
India’s enormous energy needs are compelling a huge expansion of its installed power capacities. In response to the environmental implications of these high targets, the Indian Power Ministry has mandated clean coal technologies for the new generation of power plants, and has implemented major emission controls for existing plants, including installing flue gas desulfurization (FGD) systems.
One of the world leading FGD technology providers received numerous orders for installations of FGD Systems, from a national thermal power provider. The technology provider contracted our partners in India, Kirloskar Corrocoat Pvt Ltd (KCPL), to provide corrosion protection for FGD tanks. One of the projects also included work on roller compacted concrete (RCC) sumps, trenches, tanks and the outlet ducts of an absorber.
Surface Preparation: Abrasive blasting as per SSPC SP 13 / NACE No. 6 & SP 5 Data Sheet for Concrete Substrate requirement for coating.
Coating Application:
RCC Sump RCC Trenches
Surface Preparation: Abrasive blasting as per SA 2.5/ NACE No. 2/SSPC-SP10
Coating Application:
Having already completed 3 projects in 2022, KCPL look forward to further work in accordance with the client’s ongoing projects.
Corrocoat USA were asked to apply a surface tolerant coating system to the structural steel on a pipe bridge, on site at a coal-fired power plant in Florida. The pipe bridge, spanned a 135 foot (41 meter) diameter thickener tank, which is used to clarify or separate the solids included in recycled gypsum. The solids are transported from the recycling tanks, which are upstream in the Flue Gas Desulphurization System. Once clarified, the gypsum is refined further and then sold to a neighbouring facility who use the gypsum to make drywall board, used in houses and commercial buildings.
The client hired a firm to perform an engineering inspection in the spring and were advised to replace the severely corroded steel members, and apply a suitable corrosion resistant coating to the new and remaining members. The structural steel members were corroded as a result of a reaction with the low pH vapours, that fume up from the tank beneath.
As this tank was integral to the power generation process, the project was completed during an outage. Corrocoat USA had only 2 weeks to complete the project, which included 4,700 square feet (432 square meters) of structural steel, many of which were small angles, channels and I-beams.
Working off scaffolding, the crew executed a surface tolerant specification that included pressure washing, spot preparation using angle grinders and needle guns. They then primed with Plasmet ZF; a surface tolerant two-pack epoxy coating compound incorporating a rust inhibitor and passivator, with MIO (micaceous iron oxides) and glass flake for increased protection. This was then over-coated with Corrothane AP1.
It took 12 men thirteen consecutive days, working long hours, to complete the project to the satisfaction of the customer. The team completed the project one day ahead of schedule, an impressive feat considering the intricacies/geometries of the project.
For the past two weeks we had the pleasure of hosting our partners from Corrocoat Caspian, at our head office in Leeds. Aliya Zhumanova, Corrocoat Caspian Director, joined us with Konstantin Vassilyev, Murat Jumabekov and Kirill Slavko to undergo advanced technical training.
Our Technical Supervisor, Douglas Lynch oversaw all of the training, starting the 2 weeks off with theory-based training on corrosion, service environments, specifying products and much more.
Murat, who originally joined the company as a security guard 9 years ago, worked his way through the ranks, becoming one of the leading engineers and applicators in the field. Murat was joined by fellow applicator, Konstantin, as they continued their training with practical sessions in our coating and engineering workshops. Carrying out specialist coating applications, pipe spraying, pipe wrapping and pump disassembly, Murat and Konstantin were shown the latest techniques by our leading mechanical engineers and coating specialists and applicators.
Kirill, originally joined Corrocoat Caspian as a Sales Engineer. Recently promoted to Production Manager, Krill, as part of his training, spent time with our Coating Production Manager, Mike Walsh and other members of the Corrocoat production team, to get to grips with the intricacies of the production and manufacture of our specialist coating systems.
Following their training, our CEO, Charles Watkinson, presented the team with a certificate – it was a very proud day for the group, who had thoroughly enjoyed their time with us. We are very much looking forward to hearing from Corrocoat Caspian on the exciting projects they are continuing to undertake in Kazakhstan and how their training will be put to use to further enhance the service and results delivered to their clients.
An international marine client recently commissioned our partners in Singapore, BHM Engg Services, to refurbish and provide corrosion protection for a badly corroded sewage tank. The tank had been in service around 2 ½ years and the client requested an alternative to an epoxy paint system which had already failed having suffered from chemical attack.
Polyglass Standard; a two-pack cold cured polyester/acrylic co-polymer enhanced with flaked glass, was selected for this project. Polyglass performs extremely well in immersion environments such as marine, aqueous and corrosive chemical environments.
The team began by removing the original coating and then pressure washing the tank at their workshop. It was then grit blasted before the new coating system was applied by airless spray and brush application.
The client was extremely happy with the results and the BHM team were commissioned to refurbish and provide protection for a second tank.
