Tag Archives: Belzona

Pump Group Extend Life of Power Station Pipework Using Belzona 1812 Ceramic Carbide

Pump Group were contacted to assist with an issue at a Coal Fired Power Station where the site engineers had sections of pipework which were failing within an unreasonably short period of time. The pipes are situated in part of the FGD (Flue Gas Desulphurisation) Plant part of the power station, which operates to remove harmful chemicals from the exhaust gases from the power station, specifically Sulphur Dioxide (SO2). The gasses are passed through a limestone slurry which ‘scrubs’ the SO2 from the gasses emitted. A direct product of this process is that Calcium Sulphate (CaSO3) and CO2 are created. The limestone slurry, now containing Calcium Sulphate is then pumped away for further treatment. This slurry is highly abrasive (due to the limestone) and very corrosive (due to the Calcium Sulphate), which means it wears away at pumps & pipework very quickly – the average lifetime of the pipes had been less than 6 months before pipes would need to be replaced with a new one. Pump Group engineers recommended coating with Belzona 1812 – Ceramic Carbide to provide a pipe interior which would outlast the poor performing existing pipes. To reduce the application time & to increase accuracy, Pump Group fabricators manufactured a flanged mould with a machined insert. This mould is then bolted onto the pipe prior to coating, and allows the technician to completely fill all spaces with Belzona 1812 uniformly whilst ensuring the internal dimensions are to specification. The wetted areas were shot blasted to remove all possible contaminants and also to achieve a surface profile of SA2.5 @ 75microns which is required for the Belzona to bond successfully to the substrate material. The pipes were then salt tested to confirm acceptable levels of nitrates and other contaminants which can jeopardise the longevity of the coating. The internal surfaces of the pipes were coated using Belzona 1812 Ceramic Carbide around the .  Belzona 1812 was selected as it is a composite material combining extremely hard closely packed abrasion resistant ceramic aggregates in a polymeric binder ideal for the repair and protection of substrates being damaged by particle abrasion. Following Belzona 1812 being applied on the pipes, the pipe flange faces were then final machined true using a diamond tipped tool. Pump Group had already carried out similar Belzona applications for the same client on the FGD plant and the client had seen a 50% increase in … Continue reading

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Belzona Repair of a Lined Acid Receiver – Chemical Industry

The Acid Receiver was removed from a chemical production site installation following customer concerns regarding the flange integrity and the receiver was transported  to Pump Group for repair. The tank has a metal shell lined with polypropylene and then wrapped with glass fibre.  Upon inspecting the tank, it became clear that both the PN16 Plastic flanges had been heavily corroded and were no longer safe to use in their current state. It appeared that acid had slowly leaked past the gaskets on both the flanges, and the acid had corroded through the glass fibre, the polypropylene and even the metal shell. Pump Group engineers proposed a course of action to remove the damaged flanges and rebuild new flanges using Belzona 1111 Super Metal.  Belzona 1111 was selected because it is a metal repair composite which has excellent adhesion to metals and plastics, meaning it can be used to both re-form the flanges and bond the flanges to the tank. The damaged flanges were cut off and the edges prepared by removing the glass fibre and polypropylene 2” back from the existing flanges and then grit blasting the necessary areas. A mild steel forming plate was manufactured and bushes welded on which had the same PCD and clearance hole size as the existing flanges. 2 split rings were manufactured our of 316 Stainless Steel which were located behind the flange faces. The flanges were then rebuilt with Belzona 1111 using the forming plate and split rings to ensure the correct size. Belzona 1111 was used to bond the rebuilt flanges to the tank, and the mould and split rings were released once the Belzona had cured. The OD of the Nozzles and flanges were coated with Belzona 1321 Ceramic Super Metal. Belzona 1321 is designed to provide corrosion resistance to surfaces – it has high chemical resistance which will prevent acid attack causing damage to the flanges should  leakage occur in the future. For more information on how we can utilise our extensive Belzona knowledge and Coating Facilites to assist your company with your operational needs, please contact a member of our Repairs Team on +44 (0)161 864 4678 or via email repairs@pumpgroup.co.uk.    

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Profile Recovery of Impeller using Weld & Belzona 1812 Ceramic Carbide

Our customer was experiencing issues with corrosion & erosion destroying their pump units on a Flue Gas Desulphurisation (FGD) application. Whilst purchasing the uprated impellers – made out of a more resistant Super Duplex, even then the impellers were lasting less than a year before the pumps needed removing from service for overhaul. The impeller was despatched to Pump Group with the aim of sourcing a more long term and cost effective solution rather than just replacing the impellers with new from the OEM.  Pump Group suggested rebuilding the impeller using specific Belzona Polymeric Coatings designed to withstand such damaging conditions. The impeller was bead blasted and jet washed clean, and metal inserts were fabricated to roughly rebuild the impeller profile. The inserts were then welded in to position and hard face welding carried out over the edges to increase the strength. The impeller was shot blasted to remove all possible contaminants and also to achieve a surface profile of SA2.5 @ 75microns which is required for the Belzona to bond correctly to the substrate material. The unit was then salt tested prior to coating to confirm the lack of presence of nitrates and other contaminants which can jeopardise the longevity of the coating. The surface was rebuilt using Belzona 1812 Ceramic Carbide.  Belzona 1812 was selected as it is a composite material combining extremely hard closely packed abrasion resistant ceramic aggregates in a polymeric binder ideal for the repair and protection of substrates being damaged by particle abrasion. Once the Belzona was applied (6mm thick) the impeller diameter and neck was machined with a diamond tipped tool to achieve required clearances within the pump. A mandrel was manufactured to allow the rotating element to be dynamically balanced to G2.5 at 1000 rpm. By utilising Belzona, the impeller was rebuilt in a much shorter period of time, approximately half the cost of a new impeller, and the Belzona 1812 Ceramic Carbide coated impellers achieves twice the life of the OEM impellers. For more information on how we can utilise our extensive Belzona knowledge and Coating Facilities to assist your company with your operational needs, please contact a member of our Repairs Team on +44 (0)161 864 4678 or via email repairs@pumpgroup.co.uk.  

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Belzona Protects Trench From Acid Attack

The customer was experiencing problems within a 40 metre long trench near a tanker off-loading area. Tankers carrying both Sulphuric and Nitric acid were being emptied regularly, with small amounts of acid being spilled each time. This acid had corroded through large areas of the concrete floor and trench, and there was a danger of the acid corroding through the remaining concrete and contaminating the underlying soil & water table. One of our specialist engineers attended site to survey the problem, and concluded that the extremely hard wearing yet versatile range of Belzona Polymeric Coatings would be ideal for this scenario.  The ability to apply the Belzona polymer coatings cold and the fast curing properties were ideal for this situation. Once given the instruction to proceed by the customer and all of the relevant Risk Assessments and Method Statements had been approved, a team of our factory trained Belzona approved technicians attended site to carry out the repair. They cleaned the concrete using high pressure steam cleaners, removing all traces of acids and oils to ensure the Belzona product bonded to the concrete substrate. First the technicians used Belzona 4141 Magma Build, a concrete specific repair polymer, to rebuild the concrete back to the original profile, then applied 2 coats of 4311 Magma CR1, which is a high performance coating designed to withstand the most aggressive chemical attacks. The Belzona process took our 2 engineers 8 days from start to finish, which is a lesser period than how long it would have taken to concrete the damaged areas, which would have also needed 28 days to cure. The 4311 Magma CR1 has many times the chemical resistance of concrete, meaning that the Belzona repair will far outlast any traditional repairs that could have been used. For more information on how Pump Supply & Repair Group can utilise Belzona Coatings both in our workshop and on-site, please contact our Site Services Manager, Charles Lambley, on 07887 721900, or email him on clambley@pumpgroup.co.uk

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