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KNOW - HOW

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UNIQUE SOLUTIONS FOR UNIQUE PROBLEMS

KNOW-HOW In Action 309

CORROSION PROTECTION OF Ø 600 PIPES IN CONCRETE WALL BUSHINGS

CLIENT: Chemical Plant.

APPLICATION DATE: June 2020.

APPLICATION SITUATION: Reinforcement and protection against corrosion of a Ø 600 mm pipe.

PROBLEM: A spool of a pipe that was embedded in a concrete die had to be replaced as a consequence of the severe external corrosion it had suffered.

To prevent the new spool from being exposed to differential aeration corrosion again, it was decided to protect it with Belzona prior to concreting.

PRODUCTS:
Belzona® 1121
Belzona® 9341
Belzona® 5811

SUBSTRATE: Carbon steel.

METHOD OF APPLICATION: Existing paint was removed from the reel using a grinder with sanding discs and the surface was then roughened using a Bristle Blaster. A length of approximately 50cm of the pipe was insulated and reinforced with Belzona® 1111 and Belzona® 9341 and finally the entire application was protected against external corrosion by differential aeration with our Belzona® 5811 epoxy coating.

BELZONA® RESULTS: The application was carried out in a few hours, allowing the pipe to be concreted the following day and guaranteeing very long-term protection against the corrosion common in this type of joint.

PHOTOGRAPHIC DESCRIPTIONS:

  1. Surface preparation.
  2. Screeding with Belzona® 1111 and Belzona® 9341.
  3. Application of Belzona® 5811.
  4. Pipework concreted and in service.

KNOW-HOW In Action 303

RECONSTRUCTION AND LINING OF 35% SULPHURIC ACID TANK

CLIENT: Chemical factory

APPLICATION DATE: July 2019

APPLICATION SITUATION: Tank with multiple leaks, cracking and thickness loss.

PROBLEM: Premature deterioration of the tank due to embrittlement of welded joints and continuous chemical attack.

PRODUCTS:
BELZONA® 1121
BELZONA® 9341
BELZONA® 4311

SUBSTRATE: 304 stainless steel

APPLICATION METHOD: The surface was previously cleaned according to SSPC-SP1 to remove any chemical residues. Surface was prepared by abrasive blasting according to SSPC-SP10 / NACE 2, with 75 micron anchor profile. Filled with BELZONA® 1121 and BELZONA® 9341. Two coats of BELZONA® 4311 were applied internally and externally.

BELZONA® RESULTS: BELZONA® was chosen due to the simplicity of the reconstruction and the quick return to service.

PHOTOGRAPHIC DESCRIPTIONS:

  1. Initial conditions.
  2. Surface preparation
  3. Application of BELZONA® 1121.
  4. Detail of the finish.

KNOW-HOW In Action 301

REINFORCEMENT AND ENCAPSULATION OF FUEL-OIL TANK PIPEWORK

CLIENT: Chemical Plant

APPLICATION DATE: April 2019

APPLICATION SITUATION: Encapsulation and reinforcement of a Ø 630 mm pipe.

PROBLEM: A fuel oil tank pipe had a leak that had been plugged with the help of some pipe plugs. Given the state of corrosion and the possibility of new leaks in other areas of the socket and its grafts, it was necessary to encapsulate the previous repair and reinforce the entire damaged area, but given the importance of the tank for the production process, it was not feasible to take it out of service, empty it and degas it for repair.

For this reason, it was decided to carry out an encapsulation and structural reinforcement that did not require hot work using Belzona composites.

PRODUCTS:
BELZONA® 4141
BELZONA® 1982
BELZONA® 9381
BELZONA® 5811

SUBSTRATE: Carbon steel

METHOD OF APPLICATION: The entire surface to be treated was previously cleaned and sanitised using a grinder with sanding discs, wire brushes and acetone, to roughen the surface using Bristle Blaster. The corners and bolts were encapsulated and the pipework was enlarged to a diameter of approximately 800mm using BELZONA® 4141. Subsequently the entire application was reinforced using BELZONA® 9381 (glass and carbon fibre interlocking reinforcement sheet) and our BELZONA® 1982 resin. Finally, 2 coats were applied to protect the entire application against external corrosion with BELZONA® 5811.

BELZONA® RESULTS: The application was carried out without the need for hot work, without emptying the tank and therefore without being able to remove the corners that sealed a previous leak. In three days the damaged area was encapsulated, reinforced and protected despite the geometric complexity of the repair.

PHOTOGRAPHIC DESCRIPTIONS:

  1. Initial state
  2. Re-grouting with BELZONA® 4141
  3. Application of BELZONA® 1982 and BELZONA® 9381
  4. Protection with BELZONA® 5811

KNOW-HOW In Action 298

COLD WELDING OF CRACKS IN PIPES

CLIENT: Asturian Steel Company

APPLICATION DATE: October 2016

PROBLEM: The gas flow through the pipe and the external corrosion conditions have produced a great wear and severe loss of thickness with cracks and holes. Using the BELZONA® solution, the thickness of the pipe is restored and the cracks are repaired.

SUBSTRATE: Steel

PRODUCT:
BELZONA® 1212

APPLICATION: The application was carried out on site. First the surface was prepared by grinding the worn area. The surface was cleaned with BELZONA® 9111 (N.F. cleaning agent). Repair with BELZONA® 1212.

PHOTOS:

  1. Original condition of the pipe
  2. Detail of the damage
  3. Regrouting of sections
  4. Final state of the pipe

KNOW-HOW In Action 293

PIPE REPAIR AND PROTECTION

CLIENT: Asturian Thermal Power Plant

APPLICATION DATE: May 2016

PROBLEM: The flow of water in the pipe has produced a great wear and severe loss of thickness and leaks in the pipe/wall joint. Using the BELZONA® solution, thickness is restored, leaks are repaired and it is coated to protect against external corrosion.

PRODUCTS:
BELZONA® 1831
BELZONA® 5811

SUBSTRATE: Steel

APPLICATION: The application was carried out on site. First the surface was prepared by grinding the abraded area. The surface was cleaned with belzona® 9111 (n.f. cleaning agent). Repair with BELZONA® 1161 and coating with BELZONA® 5811.

PICTURES:

  1. Original state of the pipe.
  2. Detail of the repair at the wall pipe joint.
  3. Weld thickness recovery and regrowth.
  4. Final state of the pipe.

KNOW-HOW In Action 292

REPAIRING CRACKS IN FLANGES AND SULPHURIC ACID TANKS

CLIENT: Zinc producer in Northern Spain

APPLICATION DATE: December 2015

APPLICATION SITUATION: 98% sulphuric acid tank.

PROBLEM: Corrosion of the sulphuric acid has caused breaks in the flange of a pipeline and in a tank.

SUBSTRATE: Steel

PRODUCTS:
BELZONA® 4301
BELZONA® 4311
BELZONA® 4341

APPLICATION: The application was carried out on site. First the surface was prepared by grinding the worn area. The damage was reconstructed by welding a metal roof tile with BELZONA® 4301 acid resistant mastic. The area is additionally coated with BELZONA® 4301 to increase the mechanical strength. The entire assembly is coated with the antacid polymer BELZONA® 4311 and BELZONA® 4341.

PHOTOS:

  1. Damage of the flange
  2. Repaired area
  3. Original tank damage
  4. Final state of repair 

KNOW-HOW In Action 290

H2SO4 98% TANK LINING

CLIENT: Asturian Engineering

APPLICATION DATE: January 2015

APPLICATION SITUATION: 98% sulphuric acid tank

PROBLEM: Protection of a tank containing 98% H2SO4 by applying BELZONA® 4311 protects and increases the life of the equipment against the chemical attack present.

SUBSTRATE: Metal

PRODUCT:
BELZONA® 4311(MAGMA CR1)

APPLICATION: The equipment is blasted. Two coats of BELZONA® 4311 are applied in a minimum thickness of 250 microns each. A final inspection is carried out with thickness measurement and pore detection.

PHOTOS:

  1. Deposit to be treated
  2. Condition after blasting
  3. Coating by means of BELZONA® 4311
  4. Detail of the final coating 

KNOW-HOW In Action 289

COMPREHENSIVE REPAIR OF SEVERELY CORRODED PIPELINES

CLIENT: Asturian Chemical Company

APPLICATION DATE: June 2016

PROBLEM: The flow of oil passing through the pipe and the external corrosion conditions have produced a great wear and severe loss of thickness, as well as large cracks. Using the BELZONA® solution restores the original thickness of the pipe in the damaged and leaking sections while reinforcing its protection against external corrosion.

PRODUCTS:
BELZONA® 1121
BELZONA® 5811

SUBSTRATE: Steel

APPLICATION: The application was carried out on site. First the surface was prepared by grinding the abraded area. The surface was cleaned with BELZONA® 9111 (N.F. cleaning agent). Repair with BELZONA® 1121 and coating with BELZONA® 5811.

PHOTOS:

  1. Original condition of the pipe.
  2. Detail of the repair
  3. Heavy damage to the pipe
  4. Final state of the pipe

KNOW-HOW In Action 288

CLADDING OF THE OVERHEAD CRANE IN THE DOUGH DRYING AREA

CLIENT: Paper Company

APPLICATION DATE: June 2016

PROBLEM: Corrosion by chemical attack in the area of the pulp dryer has caused severe corrosion in the bridge crane. By BELZONA® solution is coated protecting it and repairing the existing corrosion increasing the life of the same.

PRODUCT: BELZONA® 5811

SUBSTRATE: Steel

APPLICATION: Blasting of the bridge crane. Application of BELZONA® 5811 in two layers of 250 microns.

PHOTOS

  1. Original condition of the bridge crane
  2. Coated equipment.
  3. Detail of existing damage
  4. Final condition 

KNOW-HOW In Action 283

REPAIR OF GASOMETER CRACKS

CLIENT: Siderúrgica del Norte de España

APPLICATION DATE: November 2016

PROBLEM: Wear on welds and beads in the gasometer causes cracks and fissures that cannot be thermally welded due to the rubber coating are repaired.

PRODUCT:

BELZONA® 1161 – SUPER UW METAL

BELZONA® 1971 – SUPERWRAP

BELZONA® 9371 – SUPERWRAP BANDAGE

SUBSTRATE: Steel

APPLICATION: Manual preparation and cleaning of the surface. Cold welding reinforcement with BELZONA® 1161. Resin application with BELZONA® 1971 and BELZONA® 9371.

PHOTOS:

  1. General view of the gasometer.
  2. Detail of the cracks
  3. Sealing of the cracks
  4. Resin application