 VIEW ALLCASE STUDIES FOR THE PETROCHEMICAL INDUSTRY
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AUGUST 2010 "POWER" KNOW HOW IN ACTION (Tank Base Corrosion Repair)
Application was carried out in accordance with Belzona Know-How
System leaflet GSS-3.
Materials Used: Belzona® 3111 (Flexible Membrane)
Related Video: Tank Base Corrosion Repair Video
Past Rumford Know Hows:
JULY 2010 - (Containment Area Protection)
JUNE 2010 - (Water Pump Energy Savings)
MAY 2010 - (Containment Area Protection)
For nearly 50 years, Belzona has helped petrochemical companies keep plants running effectively and efficiently. With the industry shutdown period being extended, reliability is now the key to profitable production levels - and in some cases to the survival of the plant in today's competitive international marketplace.
The development by Belzona of high temperature specialized coatings, has given engineers in the petrochemical industry viable alternatives to traditional repair methods or specialized materials of construction, which can be expensive, time consuming and can still be subject to stress, crevice, galvanic and bacterial corrosion effects. |
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In large gas processing plants, Belzona systems have been used to repair and protect CO2 absorbers suffering from corrosion due to the formation of carbonic acid during the amine stripping process. Belzona® 1391 and Belzona® 1591, has been tested and used successfully with MEA, MDEA and Sulphinol at elevated operating temperatures in absorber towers and will also resist the decontamination "steaming out " processes during shutdowns. Belzona has a track record of successful applications in absorbers going back to 1994 and major users include, Pertamina, Shell, BP, Amoco - and many others.
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Belzona can also offer solutions to many other problems in the Petrochemical Industry where erosion, corrosion, and chemical attack takes its toll on process equipment including:
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Wastewater strippers where corrosive hydrogen sulphide attacks base metals/weld overlays and hot metal sprayed coatings resulting in loss of wall thickness and stress corrosion cracking. Belzona® 1591, capable of resisting the aggressive service conditions of these units at immersion temperatures up to 185°C provides a long term cost effective solution.
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Evaporators suffer corrosion and attack from chlorides at elevated temperatures. The base of these units, internally clad with 317L Stainless Steel and operating at temperatures in excess of 105°C, suffered pitting and stress corrosion cracking. Belzona® 1391 was used to protect six of these units during 1996 with excellent ongoing performance.
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Desalter vessels internally heated with steam coils are constantly under attack from a mixture of crude oil and residual salt water. The epoxy coating in this unit failed due to the elevated temperatures. Belzona® 1391 was applied during a five-day shutdown period to provide a long term solution to problems of severe corrosion.
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Heat exchangers which are an essential part of any petrochemical installation can operate in varying service conditions. These tube plates and the channels of these units in the MEK plant of a major refinery were repaired and coated during a scheduled shutdown.
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| Within any Petrochemical facility, Belzona can provide solutions to everyday maintenance problems including: |
Repair of pitting damage and leakage to pipelines.
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Bonding of pipe support pads on jetties and pipe-racks.
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Refurbishment and efficiency enhancement of pumps.
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| Concrete/Chemical Containment Areas |
Petrochemical facilities are continually faced with attack of their structures by chemicals and concrete is in constant need of repair and protection.
Belzona can offer solutions to some of the most difficult of these problems with a range of repair materials and protective coatings that can withstand many of the aggressive chemicals found in Petrochemical Plants.
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Belzona can solve problems in the areas of:
- Chemical bunds and containment areas
- Pump plinths and vessel supports
- Effluent treatment pits
- Bio-reactor clarifier tanks
- Drain channels and waste water treatment pits
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?and provide resistance to a wide range of chemicals including
- Inorganic and Organic Acids
- Alcohols
- Alkalis
- Hydrocarbons
- Oils
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Under Insulation Corrosion (UIC) costs the Petrochemical Industry millions of dollars every year and is one of the major factors associated with reliability and safety in any plant.
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Traditional insulation systems rely on metal claddings to prevent the ingress of moisture into the insulation but this type of system is continually subjected to impact damage. In addition, when the jointing materials dry out, water can easily saturate the insulation resulting in rapid deterioration of the underlying substrate.
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Belzona has a range of insulation protection and waterproofing systems capable of providing long-term protection for most types of insulation and structures, with many beneficial features including:
- Water-based easily applied by brush or spray.
- Class "0" Fire Rating.
- Low smoke and toxicity index.
- Seamless and UV resistant.
- Micro-porous allowing trapped moisture to escape.
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| These Belzona systems have proven performance in the most demanding of environments and have been shown to prevent the damaging effects of Under Insulation Corrosion (UIC) by eliminating moisture penetration.Within many plants, water ingress is a constant problem on critical structures such as control rooms and electrical substations which can lead to the shutdown of a plant. These Belzona waterproofing systems can be used in emergencies to stop water penetration in all weather and provide long-term protection. |
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