INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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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.
The Steenbras Hydroelectric Power station was the first of its kind in Southern Africa, and to date has served the city of Cape Town for over 40 years. The hydro-electricity generated is distributed by the local (municipal) grid. Two dams are located at different elevations (300m), connected by a low-pressure tunnel through the mountain, to the high-pressure tunnel / steel penstock 3.8m in diameter, which is buried below ground to reduce environmental impact.
The penstock feeds water gravitationally through four turbines, generating 180MW of electricity for the City of Cape Town. The internals were originally coated with a thin solvent-based epoxy, which blistered. The internal lining was refurbished after 18 years in service with another epoxy lining and blistered again.
Our partners in South Africa, Cape Town, were awarded the tender for the reline of the steel section of the penstock. It took 12 months of planning, design, fabrication and testing to prepare for this challenging and time sensitive project.
SCOPE OF WORK:
COATING SYSTEM USED:
SITE CHALLENGES:
Rope Access professionals were essential to installing the customized scaffold and stair system that allowed a larger work force to work. However, some areas could only be reached via rope access alone.
Despite all of the challenges, work was completed to the full satisfaction of Corrocoat South Africa’s client.
Corrocoat USA and Corrocoat Ltd recently joined forces to supply over 25,000 litres of our high performance protective coating, Polyglass VEF in combination with bespoke lamination technology, for the internal lining of a 250ft diameter crude oil storage tank.
The client – a large oil refinery in the US, were in desperate need of a vinyl ester lining to replace the existing fibreglass coating. This had failed an inspection carried out in accordance with the American Petroleum Institute (API) guidelines. The client turned to Corrocoat USA to provide the material required to reline and protect the tank floor against future corrosion.
Corrocoat USA were able to manufacture and deliver a significant portion of the product to the client. However, due to the time constraints, Corrocoat UK were also asked to arrange production and international delivery of the remaining 20,000 litres of product required. This also included Corrocoat’s Corrofill VE and Polyglass PPV.
The logistical requirements we not insignificant and both companies relished the challenges this caused. Product supplied from the UK needed to travel by airfreight, at a time were securing cargo space was at a premium.
Marta Krause, Corrocoat Ltd Shipping Manger said; “this order was a major undertaking for both Corrocoat Ltd and Corrocoat USA. There were numerous challenges we faced in terms of the supply, manufacture and shipping of the product, but I’m pleased to say as a result of our hard work and commitment the order was successfully fulfilled, within the time constraints. We have a great international network and work very closely with our licensed partners to deliver our industry leading extra-durable, corrosion protection products worldwide. It was a pleasure to work with Corrocoat USA on this order, and a great and very rewarding team effort.”
Following the supply of the Corrocoat products, the tank floor was successfully lined and has an expected life of more than 25 years. Incredibly impressed with the service, as well as the product, the client has an ongoing contract with Corrocoat USA for the manufacture and supply of products for future projects.
Josh Tankersley, Corrocoat USA General Manager, commented; “The client was extremely impressed with the whole experience. To say that we exceeded their expectations is an understatement. The client informed me that they originally thought there was no way we would achieve what we promised, and had already prepared the organization to forgo more than $10 Million per day in lost production.”
As the developers and manufacturers of specialist coatings, Corrocoat are able to guarantee a reliable supply chain and provide abrasion resistance, erosion resistance, fluid efficiency and antifouling products to solve the world’s most demanding corrosion service environments.
Contact a member of the team today to discuss our product offering.
A raw water pump in service at a combined cycle gas turbine (CCGT) power station, required a programme of refurbishment and corrosion protection, in order to prolong its service life.
Upon arrival at our workshop, the pump was stripped down and both the casing and impeller were abrasive blasted to the required cleanliness standards. The casing was then pre-machined to accommodate the coating process.
Plasmet HTE was then applied to all internals, 2mm on the casing and 1.5mm of the impeller. Plasmet HTE is a hardwearing, slip-free, three-pack, solvent-free polyamine cured epoxy screed. This coating is resistant to strong concentrations of sulphuric and other acids. It is ideal for areas requiring abrasion (and chemical) resistance. It has been used in cyclones, chemical process vessels, sugar beet pulping drums etc. Plasmet HTE is also useful for building up damaged areas of pump impellers and casings where impact or abrasion are prevalent.
The items were thickness and spark tested to 27Kv and 17KV respectively to check for holidays.
During the refurbishment process, bearing and gasket seals were replaced and the impeller was dynamically balanced. This was all completed before the pump was reassembled for dispatch and re-installation, to ensure the full protection against corrosive seawater.
Our partners in India, Kirloskar Corrocoat Pvt Ltd (KCPL), were asked to protect the internals of a new wet limestone absorber on a coal-fired power plant in Tamil Nadu, in Southern India.
The absorber is a critical part of FGD system at the plant and operates in a highly abrasive and corrosive environment. A system offering both high chemical and erosion resistance was essential to be effective in this environment.
Polyglass PPV (a holding primer) and Polyglass VEF were selected due to its proven ability to offer superior resistance and performance in aggressive conditions.
As the absorber was 41.5 m high it was divided into 4 zones in order to complete the project;
Zone 1: Bottom to 2m shell wall
Zone 2: 2m shell wall up to 19.70m and below spray zone.
Zone 3: 19.70m shell wall up to 30.20m from bottom (spray zone)
Zone 4: 30.2m Shell Wall up to 41.50m from bottom mist eliminator Zone.
Each zone was blasted, ahead of being primed with Polyglass PPV and then coated with Polyglass VEF via spray application, to minimum DFT of 4mm in Zone 1 and Zone 3, and a minimum DFT of 2mm on Zone 2 and Zone 4. The project was completed over 3 months, with a team of 30 men.
Inspection after 6 year’s service;
A KCPL team recently visited the plant to inspect the absorber following 6 years in service. Below are the results:
Zone 1:
Zone 2:
Zone 3:
Zone 4:
No defects were found at any location accessible during the inspection and visually the coating was in excellent condition at the areas which could be observed in inaccessible areas
Conclusion
Following inspection after 6 years in service, the coating was found to be in good condition without loss of thickness, despite the highly aggressive environment, throughout all zones. The team are confident the coating can further sustain another 10 years without any major issues.
