CASE STUDY
CORRODED PIPE REPAIR
Repair of corroded pipes using Belzona SuperPad
Industry: Petrochemical
Application: Corrosion repair
Products: Belzona SuperPad and Belzona 1111
Customer Location: : VIC, Australia
Application Date: Sept 2021
PROBLEM
A major Australian Oil and Gas Refinery experienced issues with thin walled pipes caused by corrosion and required a solution to extend the life of the pipelines.
An alternative to bonded steel plates was required due to the significant OHS risks posed by handling them. These plates are large, very heavy and can get very hot in the summer, making them difficult and potentially dangerous to handle. Steel plates also need to be made offsite which can cause unnecessary delays.
In addition, steel plates are often slightly over-rolled or under-rolled which can cause the repair to fail.
Belzona SuperPads installed onsite by a trained contractor under Rezitech’s supervision and bonded in place using Belzona 1111
Belzona SuperPad bonded to the pipeline
APPLICATION
The client selected the Belzona SuperPad solution as an alternative to using steel plate which can be fabricated onsite by Belzona SuperWrap-trained contractors. SuperPad is made from Belzona SuperWrap II resin and carbon/glass fibre hybrid reinforcement sheet.
Rezitech provided onsite training for all applicators, guiding them through the entire application process and assisting them in the production of the first batch of Belzona SuperPads. Using off-cuts from common pipe sizes used at the plant, the contractor prefabricated the SuperPads, ensuring they were perfectly formed for the required pipe dimensions. The SuperPads were then installed onsite by a trained contractor under Rezitech’s supervision.
First, the surfaces were grit blasted to SA 2.5, and the SuperPads were bonded using Belzona 1111. Because the SuperPads are lightweight and ergonomically friendly, they effectively addressed the client’s OHS concerns as even large SuperPads can be easily applied by just two workers. Where it was not feasible to blast the surface due to the thin pipe wall thickness, the surface was prepared by hand, and Belzona 1161 was used to resurface the pipe and bond the SuperPads.
Rezitech provided training and assistance with the production of the first batch of Belzona SuperPads
OUTCOME
The customer is highly satisfied with the SuperPad repair solution which allows contractors to quickly, safely, and efficiently extend the life of corroded pipes without the need for offsite fabrication.
Products
The petrochemical industry is regularly faced with problems such as erosion, corrosion, chemical attack, wear, abrasion and mechanical damage which cause deterioration of infrastructure and equipment over time. Rather than replacing these assets, engineers and plant managers are using Belzona’s epoxy-based metal repair composites, high temperature coatings, and linings for reliable, long-lasting maintenance solutions.
Belzona SuperPad
Belzona SuperPad is specially designed to facilitate the fast and simple, in-situ repair of through-wall and thin-wall defects on pipes and tank walls. It is a reliable alternative to welding and mitigates the need to replace defective metallic substrates, whilst providing superior strength, chemical and corrosion resistance.
Belzona 1111 (Super Metal)
A 2-part repair composite for metal repair and resurfacing based on solvent-free epoxy resin reinforced with silicon steel alloy. This repair material will not corrode and resists a wide range of chemicals. It is easy to mix and apply without the need of specialist tools and can be machined using conventional tools.
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.
More Information?
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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.
