Steel Plant by the Sea

  Enquire / contact me

Untraditional corrosion solution for an ageing plant

Equipment & Services

View from the steel plant onto the seaside
View from the steel plant onto the seaside
Corroded pipeline with temporary leak sealing repairs
Corroded pipeline with temporary leak sealing repairs
Steel Plant by the Sea
Steel Plant by the Sea
Live leak sealed with Belzona 1212
Live leak sealed with Belzona 1212

A misty summer sea breeze turns into stormy splashes in the later months, carrying salty vapours miles off the Welsh coast. As the years go by, the cycle continues, inadvertently creating a perfect recipe for corrosion at a nearby Steel Plant, where exposed pipework is located a few hundred feet off the coast. Innocent looking solution of NaCL and H2O has thus become a significant complication for this plant, which has long outlasted its original lifespan.

Pipeline corrosion

The HP & LP COG main pipeline throughout the Coke Ovens Plant has been corroding for many years. As the metal was thinning, through-wall defects started to appear. These defects allowed H2S, CO2, CO and other poisonous gases exfoliated from the process of breaking down bitumen to escape. Wooden stake insertions and plates were temporarily used to seal the leaks. These multiple small patches were never going to last, prompting a search for a more permanent solution. The conventional welding over pipework system could not be considered as the HP gas main could not be shutdown. Therefore, they turned to cold applied, coded and warranted repair systems.

Wrap system

The contract was ultimately awarded to Belzona Technosol Limited to apply Belzona SuperWrap II, a wrap system which can be designed and installed in accordance with ISO 24817 and ASME PCC-2 Article 4.1 standards.

Application commenced in September, estimated to last two weeks. The surface was manually prepared to SSPC-SP11 using grinders, avoiding grit blasting as a potential ignition source. It was no surprise that the surface preparation opened additional weeping leaks in this severely thinned pipeline. A fast curing surface-tolerant epoxy composite, Belzona 1212, with a bypass plate was used to patch the leaks. The wrap application could then commence shortly. The remaining wall thickness in this 1.2m diameter pipe was 2mm in some areas (20% of its original thickness). A wrap was designed and applied in two critical sections in compliance with ISO 24817. In sections with greater remaining wall thickness (no potential of defects going through-wall) Belzona 5831 (Super UW-Metal) was applied to isolate the metal from the external corrosive environment.

The end result

The application was completed on time and similar work is expected at the plant shortly utilizing manual surface preparation and cold applied pipe wrap systems. In the current climate, plants and their assets operate well beyond their design life and traditional repair options are frowned upon by the HSE. Cold-applied polymer systems, in turn, play an increasingly major role – extending asset lifetime without breaking the bank.
 

Posted on December 28, 2018 - (1254 views)
Belzona Polymerics
Claro Road
HG1 4DS Harrogate - United Kingdom
+44-1423 567641
View full company profile
Location
Related articles
HANNAY Works Here: Reels for Food and Beverage
Adipec 2018: 12 - 15 November 2018
DonadonSSD: The Italian Manufacturer of Rupture Discs Ensures Maximum Safety Against Overpressure
Intelligently combined
The Reel That Works for you in Food & Beverage
One Global Industry. One City. One Meeting Place.
Pneumatic Stoppers for Any Type of Pipe
Electrical Explosion Protection Equipment
Asme Approved Rupture Discs
Reliable Reel Equipment
The Italian Manufacturer of Rupture Discs
Thermally Conductive Epoxy
Fuelling Oil & Gas Rebirth
Pneumatic Stoppers
Dyneo® Motor Drive Assembly for Higher Efficiency Levels
Electrical Explosion Protection Equipment
Ion Exchange Resins (IEN): A Fundamental Component for Pharmaceutical Manufacturing
Rupture Discs SCR
Storage Cabinets
Remote area lighting systems Peli 9480 and 9490
Spiral Retaining Ring
Portable Area Lighting System 9455Z0 RALS
Flameless Venting
Clean Room Station
Compressors Control Unit
European Plant with Boosted Process Equipment Manufacturing Capability
Air Operated Hoists Profi TI
Adhesives for the Medical Industry
Natural Gas Engine Oil Lubricants
Explosion Protection and Process Safety