Industrial corrosion protection 2012
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Industrial corrosion protection 2012

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Industrial Corrosion Protection 2012 is a small endeavour to present few long term chemical, corrosion and abrasion protection jobs executed by us. ...

Industrial Corrosion Protection 2012 is a small endeavour to present few long term chemical, corrosion and abrasion protection jobs executed by us.
ProCoat Specialities Pvt. Ltd. range of products includes high performance Corrosion Resistant Coatings, Abrasion Resistant Coatings, Erosion Resistant Coatings, Chemical Resistant Coatings, Acid Resistant Coatings, Saline Corrosion Protective Coatings, Concrete Protection Coatings and Metal Rebuilding. ProCoat offers long term protection with turn-key solutions for addressing corrosion, abrasion and erosion of metal and concrete from moderate to severe duty conditions in terms of exposure to saline, immersion, gaseous, chemical and mixed duty operations with 100% solids, advanced Novolac epoxy systems designed with excellent engineering characteristics to offer tough, long lasting, reliable barrier type of protection to substrate along with uncompromised implementation of standards in execution of surface preparation, contamination removal, coating application and quality checks of before, during and after application works.

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  • 1. ProCoat Specialities provides TURN KEY SOLUTIONS to various problems related to Corrosion, Abrasion &Erosion caused due to working environment and medias in different equipments. ProCoat Specialitiesanalysis the problem, selects right product and executes the repair / coating work with thorough surfacepreparation, application and quality checks to ensure extended period of protection to the equipment.STEEL PRODUCTION POWER PLANTS CEMENT MARINEApplications Applications Applications ApplicationsAcid / Alkali Storage Tanks Acid / Alkali Tanks Ash Hoppers Ballast TanksAVGF Tanks Additive Hoppers Ash Slurry Tanks BilgesChutes Bag house Doors Boller Seal Skirts Bow & Stern ThrusterCirculation Water Pipelines Chemical Dosing Tanks Cation Tanks Bulbous NosesClarifier Arms Clinker Hopper / Chutes Circulating Water Lines Cargo TanksCO Pipelines Clinker Silo Clarifiers CondensersCooling Gas Ducts Condensers Coal Bunkers Corroded Wet LinersCooling Gas Packing Conveyor Structures Coal Chutes Discharge PipesCooling Towers Cyclone Ducts Coal Exhauster EvaporatorsDe-Watering Screens Duct Work Condenser Tube Sheets Foam TanksDM Water Tanks Gypsum Hopper / Chutes Condenser Water Boxes Gas Fan CastingsDryer Cyclones Gypsum Silo Cooling Tower Basins Gas ScrubbersElectrostatic Tar Precipators Jetty Structures Cooling Tower Fans Kort Nozzle SurfaceGas Cooling Plant Scrubber LRS Tanks Cooling Water Pumps Non-Skid FloorsGCP Pumps Preheater Structures Crest Gates Oil CoolersHoppers Pumps De- Aerators Tanks PontoonsPrimary Gas Coolers Raw Mill Fans / Casings DM Plant Tank & Floors Rudder StacksPumps Raw Water Tanks Duct Work Sea Water PumpsRaw Water Tanks RCC Foundation Protection Fuel Storage Tanks Sewage TanksScrubber SEPAX Fan Casings Guide Vanes ShaftsSGP Filter Bed Structures Ship Loader Heat Exchangers Sluice GatesSGP Stack Soft Water Tanks Hydro Flood Tunnels Sluice ValvesSGP Structures Substation Structures Hydro PenstocksSlag Reducer Cones Transformer Oil LeakagesSludge Tanks Hydro Scroll Cases FGD Hydro Wicket Gates SYSTEMSSoft Water Tanks Steel Housing PETROCHEMICALSuction Silencer Travelling Water Screens ApplicationsThickenersTop Gas Packing Scrubber Applications BaghousesTop Gas Venturi Scrubber PAPER & PROCESS Clarifiers Accommodation ModulesWet Screens PLANTS Acid / Alkali Storage Tanks Demister Sections Brine Ponds De-Watering Tanks Applications Effluent LinesWASTE WATER Condensers Acid Slurry Tanks Desulphurization Systems Lime Storage TanksTREATMENT PLANTS Precipitators Alkali Storage Tanks Heat Exchangers Baghouse Hopper & Walls Mud System Tanks Process FloorsApplications Black Liquor Tanks Offshore Platform Decks Reaction TanksAcid / Alkali Storage Tanks Centrifuges Pipeline Internal / External Recirculation PumpsAeration Tanks Chutes Process Vessels Scrubber VesselsChecker Plates Concrete Corrosion Secondary Containment Slurry PipesClarifier Arms Condensers Stacks Slurry PumpsClarifier Tanks Cooling Towers Spray DriersDe-Watering Tanks Cooling Water Pipelines StacksDigesters DM Tanks ELECTRICITY ThickenersDistribution Chambers Dust Collector Hoppers TRANSMISSION ValvesEffluent Pipelines Green Liquor Tanks & DISTRIBUTION Venturi ScrubbersInfluent Collection Channel Heat ExchangersPump Casings Paper Machine Surface ApplicationsPump Impellers Pump Casings / ImpellersSecondary Containment Reagent Storage Tanks Concrete StubsSedimentation Tanks Secondary Containment Marshalling BoxesSewer Pipelines / Tunnels Substation Structures Substation StructuresSludge Thickeners Transformer Leaks Transformer Oil LeakagesStructural Steel Works Valves Transmission TowersTrenches White Liquor Tanks
  • 2. ProCoat products are best choice for arresting online oil leakages without draining oilfrom CT, PT, transformers, MOCB, OLTC top covers, bushings, radiators, conservatortanks, welding cracks, pin holes etc. in power transmission & generation industries.ProCoat proven products applied over mild steel & galvanized iron structures insubstations to protect them from aggressive corrosion caused due to exposure tosaline salts, moisture, industrial pollutants, chemical gases and acid rain conditions.ProCoat team follows high quality standard system for surface preparation,application of coatings and quality checks in all stages of work execution. ProCoatcoatings are extending life by more than 5 years.
  • 3. ProCoat high performance advanced polymer coating systems offered to ElectricityBoards along with application services to protect their huge transmission towerslocated in aggressive chemical, saline, industrially polluted environments whereconventional paint systems like aluminium, epoxy, zinc rich paints fail in very shortperiods. In these environments ProCoat systems are absolutely protecting thetransmission towers without any sign of rusting since almost 5 years with a lifeexpectancy of 10 plus years.ProCoat provides solution forexternal protection of marshallingboxes in switchyard of electricitydepartment from saline andindustrial exposure.
  • 4. ProCoat products helps in arresting SF6gas leakage from circuit breaker. Leakageis detected from cemented portion i.e.,joining area of metal and ceramic. Step bystep method used for leak arresting andafter that reinforcement.ProCoat coating system is applied over exposed portion of radiator fins, morespecifically edges, which are prone to rapid corrosion due to welding, bending andjointing of mild steel. This protects radiator edges from corrosion and oil leakages.ProCoat coating system has excellent dielectric strength which prevent electricshocks to people operating control panels. Coating works as insulation. Also, gripsystem can be provided for easy and safe movement.ProCoat advanced polymer coating system has excellent resistance to oils, water,chemicals being spilled over concrete foundation. It acts as excellent barrier andprevents ingress, thereby extending life of concrete surface.
  • 5. ProCoat advanced polymer coating system are best choice for external protection ofstructures, process tanks, DM water tanks, bulk acid & alkali storage tanks, concretestubs etc. based on severity of corrosion and exposure to chemicals.ProCoat high performance polymer coatings protects against external corrosion ofAVGF and Compressor tanks from the effect of alkaline corrosion and water exposurefrom adjacent cooling towers
  • 6. ProCoat high performance advanced polymer coating applied for internal protection ofBlast Furnace sludge tank from corrosion and abrasion due to handling of corrosiveand abrasive slurry.ProCoat polymer coating protects Vibro-feeders externally and internally fromcorrosion and abrasion due to immersion in corrosive slag.
  • 7. ProCoat advanced polymer coating protects Thickenerinternals against corrosion and abrasion due to slurry.ProCoat advanced polymer coating protects external and internal corrosion andabrasion protection of Pumps from the effect of corrosive & abrasive slurry.ProCoat advanced polymer coating protects MS moving conveyor of Slag GranulationPlant from high temperature steam and abrasive nature of slag.ProCoat coating protects Silencer Tank internally against chemical corrosion &abrasion. High temperature chemical slurry causes metal loss resulting punctures.
  • 8. ProCoat polymer coating protects against internal chemical corrosion & abrasionprotection of these gas pipelines. ProCoat system extended life by 5 plus years ofthese ducts.ProCoat high performance polymer coating protects pipelines and reducers againsthigh abrasion and corrosion. These reducers and pipes handles high abrasive slagand slurry. Considerable life enhancement is established with ProCoat system.ProCoat advanced polymer coating applied over submerged filter bed supportingchannels and beams to protect them from abrasion, corrosion and hot waterimmersion effect as these working conditions causes high degree corrosion anderosion of structures.
  • 9. ProCoat high performance polymer coating protects pipeline external againstcorrosion, abrasion and corrosive material. Below pipelines are in various differentenvironment from mild to severe conditions and handling different medias likechemicals, water, gas etc. ProCoat products have withstood all conditions.
  • 10. After thorough chilled iron grit blasting metal reclamation is carried out over heavypitting and cavities of Scrubber using ProCoat repair, rebuilding and reclamationproduct with high cross linking. Over reclaimed surface ProCoat advanced highperformance polymer coating filled with Ceramic and Kevlar is applied to protect fromhigh temperature gaseous slurry and water impingement. This coating hasexceptionally high chemical resistance, abrasion resistance and can tolerate hightemperatures. ProCoat system effectively extended life of this scrubber by 5 plusyears without any deterioration.Initially thorough chilled iron grit blasting is carried out followed by filling pitting andcavities of Scrubber using ProCoat repair, rebuilding and reclamation productexhibiting superior engineering properties. Next, ProCoat high functionality coating isapplied to protect from high temperature gaseous slurry and water impingement.ProCoat system effectively extended life of this scrubber by 5 plus years without anydeterioration.
  • 11. Primary Gas Coolers (PGC) are exposed to ammonia vapours, hot humid steam andother corrosive emissions leading to severe chemical corrosion and metal loss. Highcondensation over this structure accelerates corrosion phenomena. ProCoat polymercoating provides long term protection to PGC’s. Coating applied after thoroughcontamination removal, copper slag blasting and with all relevant quality checks toensure barrier protection from the given working conditions.After thorough chilled iron grit blasting metal reclamation is carried out over heavypitting and cavities of guide vanes using ProCoat repair, rebuilding and reclamationproduct exhibiting superior engineering properties and high cross linking. Overreclaimed surface ProCoat advanced high performance polymer coating filled withCeramic is applied to protect from high volume and high velocity water flow fromspiral casing of hydro turbine.
  • 12. ProCoat high performancepolymer protects againstcorrosion and abrasion. Also,reduces friction.After thorough surface preparation ProCoat highperformance advanced coating is applied to protectagainst corrosion from hydrochloric acid. Coating isamine cured with high resistance to chemicals andacids.After thorough surface preparation ProCoat advanced polymer coating is applied toprotect against corrosion from aggressive chemicals and fumes from process.After thorough surface preparation ProCoat polymer coating is applied to protectagainst corrosion from aggressive chemicals and fumes from process.
  • 13. ProCoat polymer coating is applied to protect external surface of this huge equipmentagainst chemical corrosion due to exposure to ammonia vapours in presence ofmoisture and temperature.ProCoat high performance polymer coating is applied to protect internal and externalsurface of cooling water pump column, casing, bowl etc. against corrosion andabrasion due to silt in water. Surrounding environment is also corrosive.
  • 14. ProCoat polymer coating is applied to protect these screens from severe attack ofcorrosion and abrasion caused due to handling abrasive iron ore slurry.ProCoat high performance polymer coating protects this huge sludge tank (11 mtr x11 mtr) from severe attack of corrosion, erosion and abrasion. This phenomenon iscaused due to sludge coming from furnace.ProCoat polymer coating protects this iron oxide ore handling tank from severe attackof corrosion and abrasion due to iron oxide ore.
  • 15. ProCoat high performance advanced polymer coating applied after thorough surfacepreparation to protect against severe corrosion, abrasion and temperature 250oC.ProCoat high performance advanced polymer coating applied after grit blasting andcontamination removal to protect against severe attack of corrosion.ProCoat high performance advanced polymer coating, amine curing with resistance tocold wall effect is applied after grit blasting and contamination removal to protectagainst severe attack of corrosion and abrasion.
  • 16. ProCoat polymer coating protects bag house doors against extreme corrosion due tosulphuric acid and temperature.ProCoat polymer reinforced with ceramic carbide is used for rebuilding faced areas ofSepax fan. It protects against impingement and abrasion due to fine dust.
  • 17. ProCoat polymer coating appliedto hot water tank in a five starhotel to protect against corrosion.ProCoat polymer coating protects these I - beams & mild steel frames from severecorrosion due to continuous exposure to high temperature steam generated due toquenching of molten steel.ProCoat polymer coating protects external surface of Silo from saline corrosion due tosaline environment and temperature fluctuations.
  • 18. ProCoat polymer with Kevlarreinforcement is used forreclaiming damaged portions,edges and cavities ofimpeller handling abrasiveslurry. It provides mechanicalstrength and protects againstcorrosion & abrasion.ProCoat high performance polymer coating is applied internally to protect againstabrasion and externally to protect against corrosion.ProCoat polymer coating protects these towers from severe corrosion due to variabletemperature, continuous condensation, cyclic wet & dry condition on external surface.
  • 19. ProCoat high performance polymer coating protects this critical furnace coolingsystem from severe corrosion due to continuous spills of hot water.ProCoat high performance polymer coating is applied after grit blasting andcontamination removal to protect against corrosion due to chemical attack.ProCoat polymer coating is applied after grit blasting and contamination removal toprotect against corrosion due to continuous contact of acidic and alkaline wasteliquids, mud and moderate temperature.ProCoat advanced polymer coating is applied to pump impeller to ensure protectionagainst pitting, corrosion and abrasion.
  • 20. ProCoat advanced high performance polymer coating is applied to this huge thickenerhaving surface area of 1250 square metres to protect entire mechanism like rackarms, feed wall tank, centre shaft, cones etc. from severe corrosion and abrasion dueto continuous immersion and presence of high solids in slurry. Coating applied afterthorough contamination removal, copper slag blasting and with all relevant qualitychecks to ensure barrier protection from the given working conditions. Surface profileof SA 2.5 (75 microns) achieved. Salt checks, detergent washing, wet film thickness,dry film thickness and holiday spark testing was done to ensure quality.
  • 21. ProCoat polymer coating is protecting this ship loader against severe attack ofcorrosion due to saline environment as it is adjacent to sea.
  • 22. ProCoat polymer coating protects beams, pipelines, conveyor structure, bulk materialhandling equipment etc. from saline corrosion due to adjacent sea.ProCoat polymer for rebuilding is used to rebuild worn out shafts. It is machinable,exhibits excellent compressive strength and resistance to temperature on curing.
  • 23. ProCoat polymer coating protects LRS tanks internal and external against severeattack of corrosion.ProCoat repair, rebuilding and reclamation product is used to fill cavities afterthorough blasting using chilled iron grit. Over reclaimed surface ProCoat advancedhigh performance polymer coating is applied to protect internal surface from severecorrosion and abrasion.
  • 24. After thorough chilled iron grit blasting metal reclamation is carried out over heavypitting and cavities using ProCoat repair, rebuilding and reclamation product exhibitingsuperior engineering properties and high cross linking. Over reclaimed surfaceProCoat advanced high performance polymer coating is applied to protect internalsurface from severe corrosion and pitting.ProCoat repair, rebuilding and reclamation product is used to fill cavities afterthorough blasting using chilled iron grit. Over reclaimed surface ProCoat polymercoating is applied to protect internal surface from severe corrosion and abrasion.
  • 25. ProCoat advance high performance polymer coating is applied to these two silencertanks and four bends to protect against severe corrosion and abrasion.
  • 26. ProCoat polymer coating is applied to this tank after thorough surface preparation toprotect against concrete corrosion and seepage.ProCoat polymer coating protects this clarifier from severe abrasion and corrosion.
  • 27. ProCoat polymer coating is applied after thorough surface preparation to protectagainst cyclic temperature due to quenching of slag, abrasion and corrosion.
  • 28. After thorough contamination removal, detergent washing and chilled iron grit blastingProCoat advance high performance polymer coating is applied to this CG inlet cone toprotect against corrosion due to cyclic dry and wet conditions.
  • 29. ProCoat advance high performance polymer coating protects these ammonia solutiontanks external surface against corrosion due to ammonia and corrosive atmosphere.
  • 30. In order to ensure long term “absolute corrosion protection” to various substrates of critical equipment likevessels, scrubbers, ducts, pipes, pumps tanks, structures, equipment handling aggressive chemical &corrosive mediums, equipment exposed to humidity, steam, pollutants etc, ProCoat Specialities adoptsstringent quality standards for surface preparation as well as coating application, to ensure a flawless coatingsystem over structures to effectively resist corrosion phenomena.Step - 1:Surface contamination removal: In the above given corrosive environments, there are possibilities fordeposition of alkaline, acidic or salt molecules over metal surface, which causes problem for adhesion ofcoating system. ProCoat adopts suitable methods for detecting presence of contamination by means of silvernitrate test / potassium ferricyanide test / litmus test etc. and adopts respective removal methods to ensuresurface is free from contamination. If required chemical washing is done.Step - 2:Surface Cleaning: It is obvious that by using manual wire brush cleaning, corrosion / rust deposits cannotbe removed completely and these left over ferrous oxide layer will be a problem in ensuring adhesion ofcoating system. ProCoat Specialities using an advanced method of surface cleaning by means of sandblasting / copper slag blasting / chilled iron grit blasting which is a process of cleaning metal with sandparticles mixed with compressed air forced through nozzle and when directed to rusted surface it removesentire rust / corrosion deposits and virgin metal surface is exposed. This is called “Near White Metal Surface”as per Swedish standard SA2.5 finish. Blasting to an average surface roughness of 75 to 100 micron profileis highly effective in ensuring excellent bonding of ProCoat coating system.Step - 3:ProCoat coating application: Over the well prepared surface, ProCoat coating system will be appliedinitially by thin wetting coat with high hand pressure with the help of Roller / Tynex bristle brush to ensurecomplete wetting and covering the prepared surface. Once wetting is completed, second coat will be appliedimmediately to ensure recommended thickness of coating. Also, airless spray is used for coating.ProCoat coating systems are formulated with 100% solids. This means, there is no solvent in it and noaddition of thinner while application. Since the coating is solvent free, wet film given over the surface willremain same even after complete curing without shrinking and loss of film thickness. ProCoat engineers areequipped with wet film gauges as well as dry film thickness gauges for checking during application.Step - 4:Coating Film Thickness Check: ProCoat Coatings being 100% solids, there will not be any kind ofsolvents in it which influence shrinkage of film on curing. Therefore the Wet Film Thickness and Dry FilmThickness remains same. Application engineers keep measuring Wet Film thickness by means of WFTgauge in order to comply the recommended thickness over the surface while application. Similarly, on fullcure, ProCoat engineers do check the Dry Film Thickness with DFT gauge to have a cross check.Step - 5:Coating Integrity Check: Once ProCoat coating is fully dried, entire coated surface will be checked withan instrument called “Holiday Spark Tester”. By using this instrument, any manual or invisible micro poresover coating can be identified and marked for touch up works so that “a flawless coating can be achieved”.Fully applied and checked ProCoat coating system will act as barrier to aggressive chemicals and corrosivemediums ensuring complete isolation of metal surface so that equipment is protected for longer periodwithout deterioration.Step - 6:Dual protection for Life enhancement: After completion of ProCoat coating system a weather resistantpolyurethane coat is being applied based on necessity and request of customer to ensure resistance to UVrays so that ProCoat system will last longer for addressing corrosion problem.Note: The above is only a guideline. For example at times blasting is done multiple times if required.
  • 31.  Corrosion Protection System  Ceramic Repair System  Chemical Protection System  Metal Repair System  Abrasion Protection System  Floor Repair System  Concrete Protection System  Concrete Repair System ProCoat Products Are Zero VOC 100% Solids Non Hazardous To The User Non Toxic To The Environment We Keep Our Commitment Wheels Moving, Equipments Running, We are committed to provide most Plants Shining reliable innovative products and also & advice on use and application of our Executives Smiling. products. For Further Information ContactMarketing Office Registered Office601-A, Al-Karim Trade Centre, 202, Kruti Commercial Complex,Opp.Ranigunj Bus Stop, Opp. Jai Ganesh Auto Centre,M. G. Road, Near Balaji Temple,Secunderabad—500 003. A.P. 150 Feet Ring Road,Phone: +91-40-66317998 Rajkot - 360 005 (Gujarat) India.Fax : +91-40-66316998 Phone: +91 - 281 - 6540162, 6567521 E-mail: info@procoat-india.com Website: www.procoat-india.com