KNOW-HOW In Action 309
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.
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.
- Surface preparation.
- Screeding with Belzona® 1111 and Belzona® 9341.
- Application of Belzona® 5811.
- Pipework concreted and in service.
KNOW-HOW In Action 303
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.
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.
- Initial conditions.
- Surface preparation
- Application of BELZONA® 1121.
- Detail of the finish.
KNOW-HOW In Action 301
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.
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.
- Initial state
- Re-grouting with BELZONA® 4141
- Application of BELZONA® 1982 and BELZONA® 9381
- Protection with BELZONA® 5811
KNOW-HOW In Action 298
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.
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.
- Original condition of the pipe
- Detail of the damage
- Regrouting of sections
- Final state of the pipe
KNOW-HOW In Action 293
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.
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.
- Original state of the pipe.
- Detail of the repair at the wall pipe joint.
- Weld thickness recovery and regrowth.
- Final state of the pipe.
KNOW-HOW In Action 292
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.
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.
- Damage of the flange
- Repaired area
- Original tank damage
- Final state of repair
KNOW-HOW In Action 290
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.
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.
- Deposit to be treated
- Condition after blasting
- Coating by means of BELZONA® 4311
- Detail of the final coating
KNOW-HOW In Action 289
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.
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.
- Original condition of the pipe.
- Detail of the repair
- Heavy damage to the pipe
- Final state of the pipe
KNOW-HOW In Action 288
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
APPLICATION: Blasting of the bridge crane. Application of BELZONA® 5811 in two layers of 250 microns.
- Original condition of the bridge crane
- Coated equipment.
- Detail of existing damage
- 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.
BELZONA® 1161 – SUPER UW METAL
BELZONA® 1971 – SUPERWRAP
BELZONA® 9371 – SUPERWRAP BANDAGE
APPLICATION: Manual preparation and cleaning of the surface. Cold welding reinforcement with BELZONA® 1161. Resin application with BELZONA® 1971 and BELZONA® 9371.
- General view of the gasometer.
- Detail of the cracks
- Sealing of the cracks
- Resin application