RECOMMENDED PRODUCT FOR Power Plant
CASE HISTORY
Challenge
To reduce anode consumption, increase corrosion protection, and reduce maintenance spendings because the precious coating caused high anode consumption and had poor corrosion resistance, which increased maintenance costs to >$250K per year. Heat exchangers required bi-annual inspection and repair.
Solution
We decontaminated surfaces and did a grit blast to Sa 2.5 with 3 mil (75 μm) angular profile. Then, we applied ARC S2 @ 20-30 mils (500-750 μm) to all internal surfaces (tube sheets, water boxes and covers).
Result
Our client reported that anode consumption reduced by >80%, and that ARC lined heat exchangers provided >5 years of service. Over 1,500 heat exchangers have been coated at this facility.
Challenge
To repair, restore, and provide long-term protection to the deaerator vessel with expected reliability based maintenance cycle of >3 year, because the failure of previous lining exposed steel to a highly corrosive, chloride, and o2 rich environment at elevated temperature, leading to an immediate need for repair to maintain well production of o2 levels.
Solution
We did a grit blast to remove residual failed lining, decontaminated to remove chlorides, and did an abrasive blasting to Sa 2.5 with 3 mil (75 μm) surface profile. Then, we stripe coated welds with ARC S2, and spray applied 2 coats of ARC S2 with a total DFT of 32 mils (800 μm).
Result
Our client reported that it was applied in 2009, and after 5 years, no evidence of corrosion has been found and no repairs associated with protected areas have been required. This exceeded their reliability based maintenance cycle by 66%, allowing deaerators to go to a 4 year inspection cycle as opposed to 3 years.
Challenge
To fix the problem of the corroded support pins from a suspension bridge that is subjected to extreme humidity, temperatures, and corrosive environments. The corroded pins can compromise structural integrity.
Solution
We used Chesterton 763 Rust Transformer to treat the corroded parts, and then coated the treated parts with Chesterton 752 Cold Galvanizing Compound, which provides anodic protection in atmospheric or corrosive conditions.
Result
With Chesterton 763, the rust on the parts was electrochemically transformed into a protective layer that inhibits corrosion. The ultra-fine particles of Chesterton 752 act as a sacrificial coating. The anodic zinc becomes oxidized instead of the base metal. The structural integrity was restored as a result of the Chesterton 763 and 752 combined solution.
Challenge
To fix the problem of an oil refinery needing to purchase excess spare parts and equipment due to extremely long lead times and the remote location of the refinery. Due to extreme temperatures, humidity, and corrosive environment, many metal parts became prematurely corroded over time.
Solution
We washed the parts with Chesterton 338 Super Rust Remover, and then applied Chesterton 740 Heavy Duty Rust Guard to provide long-term corrosion prevention for up to two years.
Result
The rust was effectively removed from the parts with Chesterton 338, and Chesterton 740 prevented subsequent corrosion. Over $600,000 in spare parts originally destined for disposal were refurbished and saved over a two-year period.
Challenge
To restore the tank to avoid extensive plate replacement, because the previously applied coating had failed after 2 years, resulting in severe pitting and weld zone corrosion. Client had to replace 10% of the floor plate costing €175K.
Solution
We did a plate replacement in 10% of surface area, then did a grit blast to Sa 2.5 with 3 mil (75 μm) angular profile. Then, we used ARC 858 to bring back the corroded and pitted areas to 100% of their original thickness, used ARC S1PW to stripe coat weld seams, striker plates, and transition points, and applied 2 coats of ARC S1PW via heated plural component spray equipment to a total DFT of 20 mils (500 μm).
Result
Our client reported that the ARC lining is still protecting the tank after 5 years. They also reported total savings of €850,000 by using our product.
Challenge
To remove failed lining; repair and recoat to provide a positive seal on internal surfaces. The existing bitumen lining in an effluent dosing pit was failing, resulting in acid attack on exposed concrete. The plant will be at risk of environmental fines if the dosing pit leaks.
Solution
We removed failing bitumen lining on concrete and steel surfaces by high-pressure water blasting. We blast surfaces to SP10 for metal and CSP#3 for concrete. We applied ARC 791 to patch degraded concrete, and then applied ARC S1HB by heading plural component spray to a dry film thickness of 2.5mm (80-100 mils).
Result
Our client reported that the new lining continues to be free of flaws or failure as of 9+ years.
Challenge
To fix the problem of a potato manufacturing plant’s roller chains from wearing out too quickly. The dryer chains were previously lubricated with a USP white oil for H1 Status. Chain failure must be prevented to avoid large product loss.
Solution
We recommended Chesterton 690 FG Lubricant Food Grade Chain Oil to be used. 690 FG is an H1 formulated lubricant using a USP white oil base plus performance additives.
Result
Our client reported that the chain pin wear has been reduced by approximately 75%. Their plant currently buys 690 FG in bulk and in aerosol, one drum every 20 days. 690 FG is applied via oiler and an automatic dispenser.
Challenge
To fix the problem of the cold water discharge valve that failed due to lack of lubrication in the gearbox. Hardened grease seized the gears, resulting in significant downtime and labor costs. The valve could not be actuated since the drive motors “tripped out” due to overload caused by gearbox seizure.
Solution
We applied Chesterton 723 Sprasolvo into the gearbox. This penetrating oil is fast-acting, and has an excellent capillary action that quickly loosens seized, rusted parts. Then, we removed the old grease by scraping and final cleaning with Chesterton 651 Detergent Lubricating Oil. Chesterton 615 HTG #1 was also applied to prevent future seizures and to provide adequate lubrication to the gearbox.
Result
Chesterton 615 HTG #1 did not thin out, separate, or form hardened deposits. Actuator gearbox has remained trouble free for eight years. This reliability amounts to a savings of $48,213 in labor and downtime cost over that time period.
Challenge
To fix the problem of the valve positioners at a sugar mill that were previously cleaned by a conventional contact cleaner using propylene bromide, dichlorole ethylene and other aggressive solvents, which damaged the sensitive plastic and rubber components, causing the positioners to malfunction and be replaced often.
Solution
We applied Chesterton 296 Electro-Contact Cleaner to the positioners. This helped remove dust, dirt, and light oils from electrical components. Chesterton 296 is also fast evaporating, non-corrosive and safe on most plastics and rubber.
Result
The valve positioners were cleaned effectively and no longer malfunctioned. This amounted to savings of $21,373 per year in downtime and labor cost per unit. Chesterton 296 is now a stock item due to its low toxicity and low flammability risks.
Challenge
To protect machine frames with a reliable coating and avoid production losses, as constant surface exposure to water, chemicals, vapors, and high temperature affects protective coating and leads to delamination, which affects the production quality of white Kraft paper requiring repainting of the machine frame every 12-18 months.
Solution
We removed the old coating by using high pressure water wash and did a grit blast to Sa 2.5 and 3 mil (75 μm) angular profile. Then, we applied two coats of ARC S1 in alternating colors with @ 20-25 mils (500-630 μm) total DFT.
Results
Our client reported an exceeding lifetime of ARC solution of more than 7 years (4.5x previous coating), eliminated production losses, and halted machine frame corrosion.
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