Experience Sharing                     Version 2009
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various                                     ...
Long Term Corrosion Protection Solutions Provided By ProCoat Specialities Pvt. Ltd.                                       ...
Long Term Corrosion Protection Solutions Provided By ProCoat Specialities Pvt. Ltd.                                       ...
Power Transformers, CT, PT, MOCB’s Oil Leakage Arresting Executed By                                                      ...
Product Range Includes                                                                                               As a ...
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Pro Coat Experience Sharing 2009

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ProCoat wishes to share some of the jobs done by them with you.

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Pro Coat Experience Sharing 2009

  1. 1. Experience Sharing Version 2009
  2. 2. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsCO Gas Duct Internal ProtectionOperating Medium : A mixture of gases like CO, CO2, H2, O, CH4, N & Arwith suspended solids and moisture making the medium very abrasive &corrosive.Problem : The above slurry is transported by pipelines having diameterranging from 700 DN - 1000 DN. Severe abrasion & corrosion is leading topunctures within 3 years. 8 mm thick pipelines (ducts) are reduced to 3-4mm.Solution : To meet this aggressive working conditions, ProCoat offered Severe Corrosion & Abrasion Grit Blasted Surface ProCoat - Coating Appliedtheir advanced 100% solids, high performance abrasion and corrosionresistant coating system. ProCoat had taken up job on turn-key basis andcarried out grit blasting and coating application work. ProCoat product workson barrier protection principle and eliminates the ingress of corrosivemolecules through it thereby isolating metal surface absolutely to preventcorrosion. Coating is engineered to have excellent adhesion, chemical andabrasion resistance for enhancing life by forming a tough, durable coatingsystem.ProCoat Coating is protecting these ducts since almost 4 years.Customer standardized ProCoat coating and used for around 300 meterspipelines.CO Gas Cone External ProtectionOperating Medium : Inside cone high temperature gases flows causingthe shell to build high temperatures of more than 200 deg C. The shell isgetting cooled by continuous water jets to reduce the shell temperature.Problem : Cone external surface is undergoing heavy corrosion due torapid reaction of metal with water, under influence of high temperature.Around 10mm thick rust flakes are being formed leading to loss of metalthickness of the cone. Manual Chipping Water JettingSolution : ProCoat advanced 100% solids, high performance corrosionresistant coating system was used for this cone external surface. On turn-keyjob basis ProCoat carried out mechanical chipping for removal of thick rustdeposits, followed by water jetting for removing contamination and then gritblasting finally coating application work was carried out.ProCoat Coating is protecting these Cones since almost 3 years absolutelywithout allowing corrosion reaction over the surface. Grit Blasted Surface Protected with ProCoat Coating
  3. 3. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsCooling Gas & Top Gas Packing Scrubbers - InternalsProblem: Scrubbing action of high temperature corrosive gasses withhigh velocity jets of water through nozzles making inside environment highlycorrosive and acidic plus water immersion effect. Scrubber metal iscontinuously undergoing corrosive reactions leading to heavy metal loss inform of cavities ranging from 3 mm to 15 mm in 5 years time. Customer doesnot have any option other than providing external cladding.ProCoat Specialities offered highperformance metal reclamation High Level Deformities Grit Blasted Surface Rebuilding of Deformitiessystem for rectification of largedeformities to rebuild profile ofinternal surface. Top coat ofProCoat’s barrier coating systemwith exceptional chemical andcorrosion resistant coating systemhas been applied with due qualitychecks. The coating stands inexcellent condition without any rustspot even after 2 years. ProCoat Coating Applied Absolute Performance after 2 yearsCooling Gas Compressor’s Suction SilencerInternal ProtectionSilencer is handling high pressure, corrosive gases with suspendedparticles and moisture making the medium as corrosive andabrasive slurry causing erosion of metal and leading to punctures.ProCoat Specialities taken up this work and adopted thoroughhydro jetting to remove chemical contamination and then surface isgrit blasted to get a profile of 75-100 microns. ProCoatadvanced, 100% solids, barriercoating system is applied which isdesigned to withstand the abrasive,corrosive and chemical effect of slurry.ProCoat coating is found in excellentcondition even after 2 years. Coating applied over internal surface of silencer Protecting absolutely since 2 years
  4. 4. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational Conditions Abrasion Protection of Drier Cyclones Internal Surface from Hot Metal ParticlesProCoat Specialities offered a high performance, 100% solids, high temperature resistance along with superior abrasion and erosion resistant coating system for protection of internal surface of steel plant’s DrierCyclones from sliding abrasion of high velocity fine iron particles at temperature of around 250 o C. Abrasion & Corrosion Protection of Filter Bed Structures from Slag Erosion with Hot Water Immersion DutyProCoat Specialities offered a high performance, 100% solids, high temperature resistance along with superior abrasion and erosion resistant coating system for protection of filter bed structures of steel plant fromhigh abrasion and erosion of iron slag slurry. Abrasion & Corrosion Protection of Thickener Internal Rotating Mechanism from Hot Abrasive SlurryHuge steel plant’s thickener internal structures were blast cleaned and protected with ProCoat Specialities advanced Novolac polymer coating system. ProCoat coating systemmeets duty parameters like immersion conditions, resistance to abrasion and corrosion thereby enhancing the life of these structures for extended periods
  5. 5. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsSLUDGE TANK INTERNAL PROTECTIONTwo huge sludge tank of 11 mtr height x 11 mtr diameter isbeing used to handle thick, heavy abrasive slurry with wettemperatures around 70-80 deg C. Internal metal surface issubjected to high abrasion due to coarse, abrasive particlesand high wet temperatures accelerates severe metalcorrosion. ProCoat Specialities carried out thorough surfacepreparation using chilled iron grit blasting to attain SA3 finishwith 75-100 micron profile. Huge Sludge Tank Grit Blasting ProgressProCoat advanced, solvent free, abrasion andcorrosion resistant coating system was appliedto a thickness of 500 microns average.Successful protection is observed even after aperiod of 18 months and life expectancy ismore than 5 years ProCoat Coating Applied ProCoat’s Abrasion & Corrosion Protection Coat-SLAG GRANULATION PLANTSupporting I Beams & StructuresProtectionRed hot slag is being quenched with high pressure waterand is coming into this slag granulation plant producinghigh temperature steam with boiling water along withlarge quantities of abrasive slag. I Beams & otherstructures are under immersion condition and sufferingfrom high degree of corrosion and abrasion. Heavy Corrosion of I Beams Grit Blasting of I Beams ProCoat Coating AppliedProCoat Specialities carried out thoroughwater jetting and blast cleaning to obtainoptimum surface finish and profile.Over these cleaned I beams and structures,ProCoat advanced, high temperature,abrasion and corrosion resistant polymercoating system was applied to protect thesestructures from abrasive slag and boilingwater. Slag Granulation Plant Corroded Conveyor Structure Grit Blasted Surface ProCoat Coating Applied
  6. 6. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsHCL & SULFURIC ACID STORAGE TANKSExternal ProtectionProCoat Specialities carried out thorough contamination removal,surface cleaning by means of grinding to make the surface clean,dry and rough and applied ProCoat high end chemical resistantcoating system over the external surface of these storage tanks toprotect them from the spill and dripping of concentrated hydrochloricand sulfuric acids. HCL Storage Tank Contamination Removal Surface Preparation ProCoat Coating AppliedAVGF & COMPRESSOR TANKS EXTERNALCORROSION PROTECTIONSevere corrosion due to effect of hot steam and continuouswater spills occurring from adjacent cooling towers over thesetanks, ProCoat Specialities applied high performance barriercoating system with exceptional corrosion resistance overthese tanks external surface after thorough blast cleaning.These tanks are getting protected from almost 3 years with alife expectancy of 10 years. ProCoat Coating Applied ProCoat Coating AppliedPROCESS WATER STORAGE TANKSTwo huge concrete process water storage tank having atypical problem of exchanging ions from concrete andmetal into process water and causing changes in ppmwhich created problem with process.ProCoat Specialities prepared concrete surface withdetergent and fresh water cleaning and applied a barrierresistant coating system with insulation properties. Labtests of this process water was found to meet exact ppmwithout any traces of contamination ProCoat Coating AppliedRAW WATER TANK - INTERNALProCoat Coating systems were applied over fourraw water tanks internal surface to protect theconcrete surface from getting deteriorated and toenhance the life of these concrete storage tanks. Prepared Concrete Surface ProCoat Coating Applied
  7. 7. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsSLAG GRANULATION PLANTConveyor dead end structureAfter thorough blast cleaning of thisstructure applied ProCoat advancedpolymer coating system designed withbarrier protection along with abrasion andwater immersion resistance to offer longterm protection to this conveyor dead endstructures.PROTECTION OF CONVEYORSTRCTURE CONSTRUCTEDOVER SEAProCoat Specialities executed salineprotection coating system for this hugeconveyor structure by adopting copper slagblast cleaning and application of long termsaline corrosion resistant coating systemwith exceptional barrier protectionproperties from the effect of saline windsand humidity.CONVEYOR SUPPORTINGLEGS & FRAMESProCoat’s advanced saline corrosionresistant coating system is used to protectthese supporting legs and frames of thisconveyor.SHIP LOADER STRUCTURECONSTRUCTED OVER SEAProCoat Specialities executed salineprotection coating system for this hugeconveyor structure by adopting copper slagblast cleaning and application of long termsaline corrosion resistant coating systemwith exceptional barrier protection propertiesfrom the effect of saline winds and humidity.
  8. 8. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsSTEEL PLANT TOP GAS MISTELIIMINATOR & VENTURISCRUBBER INTERNALPROTECTIONContinuous contact of highly corrosive medium,scrubbing of corrosive gases with highsuspended particles and high pressure waterjets, causing severe corrosion and cavities on Problem Heavy Pitting & Cavities Grit Blasted Surface Cavities Rectificationthe internal surface of the equipment. Also,heavy metal loss in irregular fashion.ProCoat Specialities executed using chilled irongrit blasting for surface profile then metalreclamation work with advanced, highfunctionality Novolac metal rebuilding systemand further protected with high end chemical andcorrosion resistant coating system. Theequipment is performing since almost 3-4 yearsand the coating is intact. ProCoat Coating AppliedPROTECTION OF IRON SLAGREDUCERSProCoat’s ceramic lining systems are meeting protectionrequirements of this slag reducer internal surface fromthe effect of high abrasive slag and slurry movement.Coating enhanced life of these reducers from 3 moths to12 moths.PROTECTION OF PUMPHOUSE PIPELINESProCoat water resistant coating systems areused to protect these pipelines externalsurface from the effect of corrosion causeddue to continuous spill of water and pollutedfumes.
  9. 9. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsSlag Granulation PlantConveyor PulleySupporting StructuresProCoat coating system is effectivelyprotecting these structures fromcorrosion due to continuous spill ofwater and slag deposition duringoperation.CO Gas Seal Parts Cooling Gas - ConesThese gas seal parts both Huge cones handling CO gasinternal & external surface got along with suspended particlesprotected with ProCoat and slurry causing abrasion andcoating system from corrosion. ProCoat coatingaggressive abrasion and systems applied internally tocorrosion effects caused due protect from duty parameters andto handling of CO gas slurry external coating to protect fromat high temperatures. continuous water spills.Abrasion & CorrosionProtection of Guide VanesImpact of water with silt on guide vanesdevelops pits and cavities resulting in metalloss. ProCoat executed metal rebuilding ofpits and cavities then applied an advanced,100% solids coating system whicheffectively resist abrasion and corrosioneffects of water flowing from penstock. Abrasion and Erosion Protection of Francis Turbine Runner from Silt Corrosion Protection of Bridge Girders exposed to Human WasteHydro Plant’s Francis Girder top surfaceTurbine Runner vanes between rails areare coated with ProCoat suffering fromceramic system to corrosion due toprotect them from deposition of humanerosion and abrasion waste dropped fromeffect of silt and water passenger trains.during operation ProCoat applied long term protection coating system over it.
  10. 10. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational Conditions Chemical Spill Protection of Concrete Foundations Spill Protection of Kiln Roller Concrete FoundationsChemical Protection of ProcessFloorProcess floor of a chemical plant sufferingfrom corrosion and deterioration of concretedue to spills of chemicals and fluids. ProCoatSpecialities executed chemical resistant floorcoating system after carrying out thoroughsurface preparation with contaminationremoval, cleaning and drying. Chemical Protection - Drain Trench Protection of Pump House Base Frames & Concrete FoundationsDrain trenches of a chemical plant were coated with Metal base frames and concrete foundation beds get deteriorated due to continuous spillage of water during operation of pumps. ProCoat advancedProCoat chemical resistant coating system to prevent polymer coating is applied over these base frames and concrete to prevent corrosion reactions and ingress of water there by eliminating the chancesseepage of chemicals into concrete. of corrosion for extended periods.
  11. 11. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational Conditions Galvanic and Saline Corrosion Protection of Pipeline Flanges Corrosion Protection of substation Saline Corrosion Protection of Marshalling Boxes Electrical Structure Galvanic and Saline Corrosion Protection of Pipeline from saline winds and water spills Abrasion & Corrosion Protection of Raw Water Pump ImpellersCorrosion Protection of Water Pumps, Metal base frames and concrete foundation beds are get deteriorated due to continuous spillage of water during operation of pumps. ProCoat advanced polymer coating is applied over these base frames and concrete to prevent corrosion reactions and ingress of water there by eliminating chances ofMotors, Foundations from water spills corrosion for extended periods.
  12. 12. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational ConditionsSEPAX FAN ABRASIONPROTECTIONProCoat ‘s advanced ceramic system fordeformities rectification over the edges ofvanes will protect the surface from furthererosion. On top of this reclaimed area, highperformance ceramic system is brushapplied, which cures to a tough, abrasionresistant layer with extreme smooth surfaceto reduce friction and offer excellent abrasionresistance to the Sepax Fan. Grit Blasting - progress METAL REBUILDING OF SHAFTS & BEARING HOUSINGS CEMENT MILL - BAG HOUSE DOOR & INTERNAL PROTECTION ProCoat high performance advanced, chemical and corrosion protection system applied on bag house doors for protecting them from acidic corrosion at high temperature. Excellent protection since three years. LRS TANK INTERNAL & EXTERNAL METAL PROTECTION FROM CORROSIONLRS tank internal and external protection with ProCoat coating system for preventing corrosion as well to insulate the metalfrom electrolytic reactions.
  13. 13. Long Term Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Various Equipments From Aggressive Operational Conditions Corrosion & Abrasion Protection of Base Rings Long Term Corrosion Protection Coating System for cooling water pumpsProCoat Specialities protected these base rings from corrosive and abrasive ProCoat Specialities protected these big horizontal and vertical pumps from continuous water spills during operation.effect of ammoniated slurry. ProCoat executed the coating application after ProCoat high performance corrosion resistant coating system prevents corrosion of metal by providing a barrier layerthorough copper slag blast cleaning followed by application of chemical and there by eliminating ingress of water molecules.abrasion resistant coating system with due quality checks. Sugar Brine Recovery Concrete Tank Leak and Corrosion Protection SystemConcrete tank handling sugar brine is facing problem of seepage and corrosion. ProCoat Specialities concrete penetrating primer coating followed by corrosion protection system is applied. Anti-Corrosion and Smooth, low friction coating system over ceramic Slip House Hopper internal surface ProCoat applied a high performance corrosion resistant coating system with smooth low friction properties for enhancing free flow of ceramic medium as well as preventing corrosion of internal surface of this slip house hopper.
  14. 14. Long Term Corrosion Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Substation Structures From Aggressive Saline & Industrial Polluted Environment ELECTRICITY SUBSTATION — STRUCURAL PROTECTIONProCoat Advanced, 100% solids, multifunctional polymer coatings systems were used at substation structures which are located inaggressive environment comprising salinity, humidity, chemical fumes, acid rain conditions and protecting absolutely since three years. ProCoat coating systems are out performing at these environment incomparison to conventional paints, chlorinated rubber paints, zinc rich coatings & even epoxy paints of reputed make which are failing in just 12 months and causing the metal to corrode heavily. ELECTRICITY SUBSTATION — STRUCURAL PROTECTIONEquipment supporting structures like CT, PT, LA,isolator etc of substation undergo severe corrosiondue to exposure of chemical fumes along withmoisture from adjacent factory. Conventionalsystems fails to protect.ProCoat Specialities carried out turn key applicationby surface preparation, contamination removal fromthe surface and applied chemical and corrosionresistant coating system over these structures whichensuring absolute protection since four years.
  15. 15. Long Term Corrosion Protection Solutions Provided By ProCoat Specialities Pvt. Ltd. For Transmission Towers From Aggressive Saline, Chemical and Humid Conditions TRANSMISSION TOWER PROTECTION FROM ACID RAIN, CHEMICALS, SALINITY, INDUSTRIAL POLLUTIONAbove shown 132kV transmission tower is located near chemical zone and exposed to sea water from the adjacent cooling towers, emissions like sulfur dioxide, oxidesof nitrogen, moisture and other pollutants from adjacent refinery, fertilizer, chemical factories creating acid rain conditions. Galvanized Iron tower parts are undergoingsevere corrosion and loosing metal thickness in just six years. ProCoat Specialities carried out blast cleaning of tower parts and applied chemical & corrosion resistantcoating system with thorough quality checks and guaranteed performance for 5 years.TRANSMISSION TOWERSPROTECTION FROM SALINITY& INDUSTRIAL POLLUTIONNarrow based 132kV transmission towers arelocated just adjacent to sea and surroundedby chemical, fertilizer industries which areemitting corrosive substances, fumes andindustrial pollutants. Mild steel is undergoingsevere corrosion reactions as corrosive andconductive electrolyte is present over thesurface and forming thick rust flakes leadingto severe metal loss. Electricity Board has tomaintain these structures for longer periodsas this circuit is revenue generating,modifications or replacement option ispractically not possible.ProCoat Specialities thoroughly analyzed the environmental conditions and degree of corrosion and offered solution with there advanced polymer coating system which is designed with barrier protection properties,solvent free, chemical and corrosion resistance. ProCoat Specialities taken up the work on turn-key basis and executed the work by sand blasting of entire tower on-line and applied coating system along with UVresistant topcoat. Guaranteed the performance for minimum 5 years with a life expectancy of 8-10 years.
  16. 16. Power Transformers, CT, PT, MOCB’s Oil Leakage Arresting Executed By ProCoat Specialities Pvt. Ltd. Without Draining Oil From EquipmentProCoat Specialities offers proven oil leakage arrestingproducts with specific and relevant properties like ability tobond on oily surface, rapid curing properties, nil shrinkageafter curing and high temperature resistance and flexibility.ProCoat Specialities has hands on expertise for providingeffective solution to oil leakages from various oil filledequipments like power transformers, CT, PT & MOCB’s etc.Oil tends to leak from various parts of these equipment likebell covers, flanges, bushing seating areas, OLTC chambers,Inspection covers, pipes, butterfly valves, radiator fins, LV &HV bushing flanges etc.ProCoat has a set of products for arresting leaks from bolts,instant sealing of leaks from flanges, reinforcement of initiallyarrested leaky areas.ProCoat provides services for attending oil leakages on-linewithout draining oil from the equipment.As of now ProCoat Specialities has provided effectivesolutions for oil leakage arresting to approximately 50- 60substations of 132kV & 220kV rating.ProCoat Specialities can provide turn-key solutions right frominspection of leaks, assessment of quantities of productsrequired and also offering services by executing surfacepreparation and application of products.
  17. 17. Product Range Includes As a solution provider, ProCoat Specialities Pvt. Ltd. takes utmost care: Corrosion Protection System ProCoat Products Are Zero VOC  In proper analysing of problem and its causes. Chemical Protection System 100% Solids Abrasion Protection System Non Hazardous To The User  In narrowing down of product selection for ensuring Non Toxic To The Environment utmost performance. Concrete Protection System  In micro planning for job execution Ceramic Repair System Our Commitment Metal Repair System  For mobilizing application specialists and equipment We are committed to provide most for execution of critical jobs. Floor Repair System reliable innovative products and also To ensure desired surface preparation by means of Concrete Repair System advice on use and application of our  copper slag / chilled iron grit / sand blasting. products.  In removing contamination and salts.  For coating application to the utmost precision. We Keep Wheels Moving,  To ensure integrity of coating application with appropriate quality checks like thickness, holiday Equipments Running, spark testing. Plants Shining &  To enhance the service life of equipment / substrate. Executives Smiling.  To ensure value to the money spent. For Further Information Contact Registered Office Marketing Office 202, Kruti Commercial Complex, 601-A, Al-Karim Trade Centre, Opp. Jai Ganesh Auto Centre, Opp.Ranigunj Bus Stop, Near Balaji Temple, M. G. Road, 150 Feet Ring Road, Secunderabad—500 003. A.P. Rajkot - 360 005 (Gujarat) India. Phone: +91-40-66317998 Phone: +91 - 281 - 6540162, 6567521 Fax : +91-40-66316998 E-mail: info@procoat-india.com Website: www.procoat-india.com

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