CASE STUDY
HEADER PIPEWORK REPAIR
Repair and Restoration of High-Temperature Pipework
Industry: Mining
Application: Repair & Restoration of Holed Converter Header Pipework
Products: Belzona 1511, Belzona 1593, Belzona SuperWrap ll, ReziSafe FP29
Customer Location: : WA, Australia
Application Date: Mar 2024
PROBLEM
The pipework on a converter hood steam condenser header used at a nickel smelter experienced corrosion, leading to through-wall and thin-wall defects that required repair.
A solution was required that could endure temperatures of around 100°C and exposure to a slight acidic product, while also providing coverage of 3.5 square meters on the header.
Header pipework showing through-wall and thin-wall defects
Pipe repair area grit blasted and cleaned with ReziSafe FP29
APPLICATION
To ensure effective pipe repair, restore wall thickness, and deliver long-term corrosion protection at high temperatures, a repair system was selected comprising Belzona’s high-strength composite wrap SuperWrap II combined with pre-rolled doubler plates, cold bonded to the pipe using Belzona 1511 (Super HT-Metal), a high temperature epoxy repair composite.
SURFACE PREPARATION – Plates and Application Areas
The doubler plates and pipe repair areas were grit-blasted to achive the required surface profile. All surfaces were then cleaned with ReziSafe FP29 Safe Solvent (Cleaner Degreaser) to ensure optimal cleanliness.
The doubler plates and pipe repair areas were grit-blasted to achive the required surface profile. All surfaces were then cleaned with ReziSafe FP29 Safe Solvent (Cleaner Degreaser) to ensure optimal cleanliness.
STEP 1: Hole Patching – Belzona SuperWrap II
SuperWrap II sheets, which have been pre-cut and pre-coated with Belzona 1983 High Temperature Grade Resin were laid onto the holed areas of the header pipes and pressed into position by means of a roller.
SuperWrap II sheets, which have been pre-cut and pre-coated with Belzona 1983 High Temperature Grade Resin were laid onto the holed areas of the header pipes and pressed into position by means of a roller.
STEP 2: Overcoating with Belzona 1593 High Temperature Epoxy Coating
Belzona 1593, a high -temperature epoxy coating designed to deliver long term corrosion and chemical resistance to equipment operating under continuous immersion up to 160°C, was applied over the Belzona SuperWrap ll to provide enhanced chemical protection.
Belzona 1593, a high -temperature epoxy coating designed to deliver long term corrosion and chemical resistance to equipment operating under continuous immersion up to 160°C, was applied over the Belzona SuperWrap ll to provide enhanced chemical protection.
STEP 3: Plate Bonding with Belzona 1511
The doubler plates were applied and cold bonded using Belzona 1511 (HT), in addition to the SuperWrap II patches. Belzona 1511 (HT), is a high-temperature repair compound designed for metal repair and equipment rebuilding, offering excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150°C. Surfaces were thoroughly wetted out, and an additional layer of Belzona 1511 was applied to the surface of the pipe to fill any pitting and restore the surface back to its the original profile. The doubler plate was then pressed onto the pipe and held in place until the product dried.
The doubler plates were applied and cold bonded using Belzona 1511 (HT), in addition to the SuperWrap II patches. Belzona 1511 (HT), is a high-temperature repair compound designed for metal repair and equipment rebuilding, offering excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150°C. Surfaces were thoroughly wetted out, and an additional layer of Belzona 1511 was applied to the surface of the pipe to fill any pitting and restore the surface back to its the original profile. The doubler plate was then pressed onto the pipe and held in place until the product dried.
Belzona SuperWrap II sheets laid onto holed areas
Doubler plate cold bonded onto SuperWrap II using Belzona 1511 (HT)
OUTCOME
The repair was successfully completed, resulting in an effective and long-lasting solution that fully satisfied the thermal and chemical resistance requirements of the application.
More Information?
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Products
Belzona 1511 (Super HT-Metal)
A two-part repair composite based on a solvent-free epoxy resin reinforced silicon with steel alloy. This high temperature repair system is designed for metal repair and rebuilding equipment and provides excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150 °C (302 °F).
Belzona 1593
A 2-part hand-applied epoxy coating designed to provide long-term corrosion and chemical resistance to equipment operating in continuous immersion at temperatures up to 160°C (320°F).
This coating has a long overcoat window and its cold curing mechanism with full in service cure reduces downtime and ensures rapid return of equipment to service.
ReziSafe FP29 Safe Solvent
FP29 Safe Solvent has been created as a direct replacement for Acetone and MEK in the workplace. This product provides a much safer alternative for those who regularly use these products and are exposed to its hazardous elements. FP29 Safe Solvent uses its patented technology to reduce these health risks and provide a product with increased performance on all levels.
About Rezitech
Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power, water and waste water, pulp and paper, marine, manufacturing among others.
We value growth and innovation within the maintenance solutions industry
Our Mission
To provide industry with easier maintenance solutions that provide cost effective, efficient and long lasting results for our valued clients. To provide an integrated industry service by striving for Rezitech being a truly complete solutions provider!
Our Values
We value the needs of our clients and place a huge emphasis on providing specialist skills and knowledge.
From engineering to fitting, blasting or coating to sales, administration and customer service, we highly value our organisation and encourage diversity andgrowth to benefit our client and our team of people.
Our Vision
To strive for excellence in our delivery of high quality industrial maintenance solutions. To be our clients’ preferred choice when it comes to solving all of their maintenance and new pump needs while helping to reduce their carbon imprint.
Health and Safety
Rezitech is committed to ensuring the health, safety and welfare of its employees, contractors, visitors and customers who may be affected by Rezitech’s operations. We strive to pursue standards of safety that meet and exceed statutory duties.
Community & Environment
While providing solutions for our clients Rezitech focuses on identifying ways to improve business environmental performance while increasing productivity and reducing costs of production for the benefit our clients and hence the community.
The Future
To continue to strive for excellence! To continue to lead the way in industrial maintenance solutions and services and provide our clientele with high quality, complete and reliable products and services.
Rezitech’s mission is to make its liquid ring vacuum pump expertise available to sugar mills, paper mills and process industries worldwide. We currently export to:
- Fiji
- Thailand
- Mauritius
- Indonesia
- United Kingdom
- Phillipines
- Malaysia
- New Zealand
- Papua New Guinea
We are constantly on the look out for new export opportunities and new countries to export to Rezitech places an emphasis on the development of export business worldwide.
For further information on a Flowtech Distributorship please contact us.
