CASE STUDY
REFINERY FEED LINE SPOOL REPAIR
In-Situ Repair of a High-Temperature 400NB Spool
Industry: Mining
Application: High-Temperature Spool Repair
Products: Belzona 9341, Belzona 1251
Customer Location: : WA, Australia
Application Date: May 2020
PROBLEM
Inspection of a 400NB spool on an alumina refinery’s Cyclone Feed Line identified significant wall loss, with areas reduced from the original 9.56mm thickness to approximately 3mm.
Operating at approximately 80°C and carrying caustic slurry, the pipeline was a critical asset, with failure potentially reducing site production capacity by up to 50%. Ultrasonic testing of the weld before the neck of the spool could not be completed due to access and geometry limitations.
As replacement was not possible during the unplanned shutdown, and the live equipment was located in a difficult-to-access area, rope access was required to complete the repair safely and efficiently.
Alumina refinery Cyclone Feed Line Spool in need of repair
APPLICATION
To address the thin-wall defect, a repair system combining Belzona 1251 (HA-Metal) and Belzona 9341 Reinforcement Tape was selected.
Belzona 1251 (HA-Metal), is a durable, single component metal repair composite based on a silicon alloy blended with a heat-activated epoxy resin. Designed for application onto hot surfaces between 70°C and 150°C, it allows repairs to be completed with minimal surface preparation, helping to avoid production downtime. Once cured, this 100% solids repair composite provides excellent corrosion protection.
A dry wrap of Belzona 9341 Reinforcement Tape was first carried out to determine the required length and coverage. Once confirmed, a thin layer of Belzona 1251 was applied to all prepared areas, ensuring the material was firmly worked into the surface profile. The Belzona 9341 Reinforcement Tape was then fully wetted out with Belzona 1251 and applied coated-side down onto the repair area. The tape was wrapped firmly around the pipe until the Belzona 1251 was forced through to the outer surface, confirming full saturation and consolidation of the wrap.
A further layer of Belzona 1251 was then applied at approximately 6mm thickness to completely seal the repair surface and provide additional protection.
Spool condition prior to repair
Repaired 400NB Feed Line Spool
OUTCOME
The Belzona 1251 and Belzona 9341 repair system provided a practical in-situ solution for restoring a critical live asset without removing the spool from service.
The heat-curing capability of Belzona 1251 allowed the repair to be completed directly onto the hot operating surface, reinstating protection to the thin-wall area while reducing the risk of failure and avoiding additional production downtime.
More Information?
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Products
Belzona 1251 (HA-Metal)
A durable, single component metal repair composite based on a silicon alloy blended with a heat-activated epoxy resin.
This heat-activated material can be applied directly onto hot surfaces (70-150°C / 158-302°F) with minimal surface preparation avoiding production downtime. Once cured, this 100% solids repair composite provides outstanding corrosion protection.
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.
