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ProCoat Specialities Pvt. Ltd. with an honest endeavour in offering turn key solution in the fields of refurbishment and specialty protective coatings for your industry by providing outstanding products backed by efficient services. ProCoat products are very well techno – economically balanced thus enabling us to provide you with the latest and the best cost beneficial repair and maintenance solutions. ProCoat’s turn key solution for protection of metal / concrete substrate is by systematic examination, analyzing root cause of corrosion, narrowing down product selection, recommending desired protection mechanism to serve the specific purpose for extended period by supplying right product and application execution with stringent surface preparation and quality check standards. In order to establish necessary genuine protection with application of coating system, one needs to opt for exemplary surface preparation of the substrate which is very important, most crucial and is a must. We at ProCoat strongly believe in Quality Work Execution and uncompromisingly follow stringent surface cleaning methodology. Irrespective of the dimensions, shapes and lengths, surface is Blast Cleaned to attain the desired Surface Finish as per Swedish Standards (Sa2.5 / Sa3) along with optimum Surface Profile (roughness), by proper work plan while adhering to safety standards. We are well equipped with necessary infrastructure required for the work execution. Though this method of Blast Cleaning is tedious and cumbersome procedure, yet we adopt the system for all applications to obtain the best possible results. Let us go through the procedures & practices adopted by ProCoat during wok execution and then we shall have a glance to some of the jobs executed by ProCoat.

Introduction

Protection Methods Adopted by ProCoat

ProCoat Coating Systems Performance Characteristics

For Retaining DIMENSIONAL STABILITY of structure / equipment without deterioration, Bare minimal maintenance for assured periods of protection without underneath corrosion,

Absolute metal protection in the given harsh environment / fluid / chemical exposures, Avoiding the need for replacement of structure / equipment

To meet this: “Metal surface has to be isolated from the physical & electrical contact of corrosive electrolyte by

means of a shielded coating system for extended periods” If this is achieved then corrosion of metal is prevented.

To meet this, ProCoat coating systems are designed with exceptional engineered characteristics in offering Barrier Protection, Chemical, Temperature, Abrasion and Impact Resistant, making it a

Durable & Dependable system in achieving absolute protection of metal in several industries for many years.

Advanced Chemistry of Coating Complex Polymer Functionality Solvent Free / 100% Solids 3 - 3.6 Cross Linking Mechanism Salt Fog / Undercut Resistance Tg-Glass Transition Temperature Chemical Spill / Immersion Resistant Abrasion / Impact / Tensile Strengths Resistance to Chemical Exposure

Single Coat System Barrier Properties VOC Nil Humidity Resistance Di-Electric Strength Toughness / Durability Temperature Resistance UV / Colour Coding

Mechanical & Chemical Features of ProCoat Coating Systems

Corrosion Basics Ore which is in STABLE state when converted in to METAL form, turns out be very ACTIVE. In a piece of metal, Anodic & Cathodic areas are formed automatically due to potential difference, impurities & surface irregularities. Electron & ionic conduction takes place in presence of electrolytic medium to complete an electric circuit. Corrosion is an electrochemical reaction of metal with electrolyte (i.e., medium in contact with metal). In corrosion reaction, metal starts forming oxide layers in the form of flakes, pitting and cavitation leading to loss of metal thickness and mechanical strength. Negligence leads to replacement of structure or equipment.

In all forms of corrosion of metal, fundamental influencing parameter is the Physical & Electrical Contact of Electrolyte (environment / medium) with Metal

Corrosion Rate Increases With Contact of Moisture - Water - Seawater - Steam - Chemical Fumes - Alkalis - Acids - Mixed Medium

SYNOPSIS ProCoat Metal Reclamation & Corrosion Protection

Works at Various Industries STEP / TASK DESCRIPTION PURPOSE EXECUTED BY

PERMITS Work Permit & Confined Space Entry

Permit, Authorising ProCoat Team to take

up work.

As per the Company/Industry Rules to ensure safety, hazard free working environment and to evaluate the progress and nature of work.

Given by Industry/Company & Followed by

ProCoat Team.

SCAFFOLDING Arrangement of relevant scaffolding

system.

Comfort and ease to access vessel / equipment surface for jet cleaning, blast cleaning, to carry out application work and quality checks.

ProCoat Team.

JET CLEANING High pressure water jet cleaning.

Removal of heavy deposits of mud, lumps, sludge from surface to facilitate access to surface and entry of ProCoat team for hassle free working condition.

Customer / ProCoat Team.

SURFACE EXAMINATION

First round of high pressure blasting

using abrasive media.

To eliminate the loose rust, thick rust flakes for revealing the parent substrate surface and take up further surface preparatory action.

ProCoat Team.

CONTAMINATION REMOVAL

Thorough detergent cleaning followed by fresh water cleaning.

To ensure the substrate is free from visible / invisible / absorbed salts / oil / chemicals over surface. Followed by contamination checks as per international standards.

ProCoat Team.

SURFACE CLEANING

Second round of high pressure abrasive

blast cleaning.

Achieving essential surface profile as per Swedish Standard of SA 2.5 / 3 (near white metal finish). Will be practiced as per the need.

ProCoat Team.

SURFACE CHECKS Profile measurement. Measuring surface profile / roughness using Elcometer Surface profile Gauge.

ProCoat Team

METAL RECLAMATION

Application of Novolac metal repair system.

Rebuilding cavities, pits and crevices formed over surface to regain metal thickness and prevent further loss.

ProCoat Team

METAL PROTECTION

Application of ProCoat Advanced Polymer

Coatings.

Application of selected coatings based on working conditions to meet the needs for long term chemical and corrosion protection.

ProCoat Team

Thickness Measuring coating thickness with Elcometer WFT & DFT gauges.

ProCoat Team

COATING CHECKS Integrity Checking coating integrity with DC

Holiday Spark Tester and rectification done to attain utmost precision.

ProCoat Team

HOUSE KEEPING & PERMIT RETURN

Work completion activities

Returning clean area by completing relevant house keeping activities. Apprising work completion to customer and returning permits.

ProCoat Team

Quality Standards Maintained Surface Preparation & Coating Application

2. Surface Contamination check

4. Grit Blast Cleaning

1. Corroded Surface

3. Contamination Removal

5. Blast Cleaned Surface

7. Surface Profile Elcometer Testing

8. ProCoat Coating Application

9. Wet Film Thickness Check by Elcometer

10. Dry Film Thickness Check

by Elcometer

11. Coating Integrity check by Elcometer DC Holiday Spark

Tester

12. Fully Completed ProCoat Coating

13. House Keeping

6. Profiled surface

ProCoat service personnel strictly adhere to both personal safety as well as site safety. PPEs like full body harness, fall arrestors, blasting helmet, air breather, blasting suit, full body apron, hand gloves, ear plugs, goggles, chemical masks, grip gloves, safety shoes, safety helmet, rubber chemical gloves used towards personal safety. On site for accessing heights, scaffolding, grip descender, safety nets, life lines are used towards work safety. All service personnel undergo routine health checks, training programs towards works at elevation and confined space entry work executions. First aid kits are kept available at site round the clock. ProCoat service personnel are trained to arrange cup lock scaffolding system along with scaffold platforms to access elevated surfaces. All PPE’s, scaffolding material are from reputed manufacturers with certification. Quality Work With Safety is practiced by ProCoat Service Team.

Safety During Work Execution(Adopted Systems At Sites)

RUST GRADE D : NEAR WHITE METAL FINISH: Very thorough blast cleaning. Mill scale, rust and foreign matter shall be removed to the extent that only the virgin metal remains without stains in form of spots or stripes. Finally, surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It shall correspond in appearance to the prints designated Sa 2½ with an acceptable profile.

RUST GRADE D : WHITE METAL FINISH: Blast cleaning to pure metal. In-spite of having D grade rusting on surface, when blast cleaned with chilled iron grit, entire rust, stains, foreign substances gets removed to expose virgin metal surface with optimum greyish colour with excellent surface roughness of 100+ microns. Surface appears to the prints designated to Sa 3.

Blast Cleaning Implemented Methods at Site Media Used For Blast Cleaning Coarse River Sand: Rough, contamination free, river sand is being used for “Sand Blasting” at places of electric induction problem. With this sand medium, near white metal finish along with an average 35 microns surface roughness can be produced on metal surface. Copper Slag: Particle size varying from 0.5mm to 2.5mm, superior quality is being used as blast medium to remove thick rust flakes and old paint layers from mild steel surface and to produce near white metal finish of SA2.5 surface finish with an average surface roughness of 75-100 microns on surface. Chilled Iron Grit: Granule size of 1mm angular chilled iron grit is used for optimum cleaning requirements where high degree of corrosion deposits from surface is to be removed. This method produce SA3 - white metal finish with an average surface profile of 125+ microns. Intended more specifically for vessel internals.

POWER PLANTS Applications

Ash Hoppers Ash Slurry Tanks Boller Seal Skirts Cation Tanks Circulating Water Lines Clarifiers Coal Bunkers Coal Chutes Coal Exhauster Condenser Tube Sheets Condenser Water Boxes Cooling Tower Basins Cooling Tower Fans Cooling Water Pumps Crest Gates De- Aerators Tanks DM Plant Tank & Floors Duct Work Fuel Storage Tanks Guide Vanes Heat Exchangers Hydro Flood Tunnels Hydro Penstocks Hydro Scroll Cases Hydro Wicket Gates Steel Housing Travelling Water Screens

PAPER & PROCESS PLANTS Applications

Acid Slurry Tanks Alkali Storage Tanks Baghouse Hopper & Walls Black Liquor Tanks Centrifuges Chutes Concrete Corrosion Condensers Cooling Towers Cooling Water Pipelines DM Tanks Dust Collector Hoppers Green Liquor Tanks Heat Exchangers Paper Machine Surface Pump Casings / Impellers Reagent Storage Tanks Secondary Containment Substation Structures Transformer Leaks Valves White Liquor Tanks

STEEL PRODUCTION

Applications

Acid / Alkali Storage Tanks AVGF Tanks Chutes Circulation Water Pipelines Clarifier Arms CO Pipelines Cooling Gas Ducts Cooling Gas Packing Cooling Towers De-Watering Screens DM Water Tanks Dryer Cyclones Electrostatic Tar Precipitators Gas Cooling Plant Scrubber GCP Pumps Hoppers Primary Gas Coolers Pumps Raw Water Tanks Scrubber SGP Filter Bed Structures SGP Stack SGP Structures Slag Reducer Cones Sludge Tanks Soft Water Tanks Suction Silencer Thickeners Top Gas Packing Scrubber Top Gas Venturi Scrubber Wet Screens

WASTE WATER TREATMENT PLANTS Applications

Acid / Alkali Storage Tanks Aeration Tanks Checker Plates Clarifier Arms Clarifier Tanks De-Watering Tanks Digesters Distribution Chambers Effluent Pipelines Influent Collection Channel Pump Casings Pump Impellers Secondary Containment Sedimentation Tanks Sewer Pipelines / Tunnels Sludge Thickeners Structural Steel Works Trenches

FGD SYSTEMS Applications

Baghouses Clarifiers Demister Sections De-Watering Tanks Effluent Lines Lime Storage Tanks Precipitators Process Floors Reaction Tanks Recirculation Pumps Scrubber Vessels Slurry Pipes Slurry Pumps Spray Driers Stacks Thickeners Valves Venturi Scrubbers

MARINE Applications

Ballast Tanks Bilges Bow & Stern Thruster Bulbous Noses Cargo Tanks Condensers Corroded Wet Liners Discharge Pipes Evaporators Foam Tanks Gas Fan Castings Gas Scrubbers Kort Nozzle Surface Non-Skid Floors Oil Coolers Pontoons Rudder Stacks Sea Water Pumps Sewage Tanks Shafts Sluice Gates Sluice Valves

ELECTRICITY TRANSMISSION & DISTRIBUTION Applications

Concrete Stubs Marshalling Boxes Substation Structures Transformer Oil Leakages Transmission Towers

PETROCHEMICAL Applications

Accommodation Modules Acid / Alkali Storage Tanks Brine Ponds Condensers Desulphurization Systems Heat Exchangers Mud System Tanks Offshore Platform Decks Pipeline Internal / External Process Vessels Secondary Containment Stacks

CEMENT

Applications

Acid / Alkali Tanks Additive Hoppers Bag house Doors Chemical Dosing Tanks Clinker Hopper / Chutes Clinker Silo Condensers Conveyor Structures Cyclone Ducts Duct Work Gypsum Hopper / Chutes Gypsum Silo Jetty Structures LRS Tanks Preheater Structures Pumps Raw Mill Fans / Casings Raw Water Tanks RCC Foundation Protection SEPAX Fan Casings Ship Loader Soft Water Tanks Substation Structures Transformer Oil Leakages

ProCoat Specialities provides TURN KEY SOLUTIONS to various problems related to Corrosion, Abrasion & Erosion caused due to working environment and medias in different equipment's. ProCoat Specialities analysis the problem, selects right product and executes the repair / coating work with thorough surface preparation, application and quality checks to ensure extended period of protection to the equipment.

DM Water, Bulk Acid, Alkali & Process Tanks The external surface of these tanks are exposed to aggressive chemicals, alkalis, acids, fumes, gases, moisture and at some places its combination of the same, which lead to severe deterioration of metal surface in spite of having epoxy based paints over them. It can be seen in the pictures below. On determining type of corrosion due to working parameters and environment, standard application procedures were followed. Surface was blast cleaned thoroughly ensuring contamination free surface and attaining required surface roughness. Over the prepared surface ProCoat chemical and corrosion resistant coating system was applied for external protection of these structures, process tanks, DM water tanks, bulk acid & alkali storage tanks, concrete stubs etc. followed with quality checks to meet the desired thickness & ensuring coating integrity.

Compressor & AVGF Tanks ExternalIndustrial pollution, alkalis and adjacent cooling towers were the main cause of corrosion on the external surface of these tanks. Stringent surface preparation standards were adopted. ProCoat coatings applied with required checks to extend life of these tanks. Some of AVGF and Compressor tanks have already crossed five plus years of life.

Some critical structures in DM Plant were taken up for protection using ProCoat Coating Systems. These structures were getting corroded due to chemical attack and acidic fumes generated by surrounding acid handling vessels. In order to have proper protection & ensure safety, these structures were protected to a height of 5 meters from ground level to retain strong structural base.

Electrostatic Tar Precipitator There are six such electrostatic tar precipitators whose external surface were to be protected. Ammonia vapours are constantly in touch with these ETPs causing severe corrosion. The extent of problem is visible in below photographs. Six such ETPs are being protected since 2 years. External surface of these ETPs were initially cleaned by means of copper slag blasting followed by contamination removal, neutralization of surface by water washing. Second round of blast cleaning was done to ensure contamination free substrate and desired surface roughness. Over this prepared surface ProCoat Coating was applied by means of Airless Spray method. On cure, coating thickness and coating integrity checks were measured to ensure complete film integrity in order to protect mild steel surface from adverse effect of ammonia vapours and other chemical exposure conditions.

Pre Cooling Towers External surface of these critical PCTs undergoing rapid and aggressive chemical corrosion due to continuous exposure of ammonia vapours, moisture and other process pollutants. Entire surface of PCTs were blast cleaned, water washed to remove contamination. Second round of blast cleaning carried out to ensure surface was neutralized and had desired roughness profile. Arrangement of safety systems helped in accessing all parts of this huge equipment to ensure proper application of ProCoat coating system over cooler sides and shell sides of these PCTs.

Tank External

ProCoat advance high performance polymer coating protects external surface of these tanks against corrosion due to chemicals, fumes, moisture and corrosive environment surrounding them.

Due to exposure to chemical vapours like sulphur, ammonia along with moisture and temperature this aluminized surface is getting deteriorated severely. Entire boiler surface was blast cleaned to remove deteriorated aluminium and corrosion deposits. Surface was neutralized with detergent and water washing. Later the surface was blast cleaned again with chilled iron grit to get SA3 finish attaining 125 microns surface profile. Over this optimized clean surface ProCoat advanced chemical corrosion protection coating system was applied and completed all quality checks such as film thickness measurement and spark testing for coating integrity in order to protect metal from corrosion causing agents.

Decomposition Boiler

After thorough contamination removal, detergent washing and chilled iron grit blasting, ProCoat advance high performance polymer coating is applied to this CG inlet cone to protect against corrosion due to cyclic dry and wet conditions.

Primary Gas Coolers (PGC) are exposed to ammonia vapours, hot humid steam and other corrosive emissions leading to severe chemical corrosion and metal loss. High condensation over this structure accelerates corrosion phenomena. ProCoat polymer coating provides long term protection to PGCs. Coating applied after thorough contamination removal, copper slag blasting and with all relevant quality checks to ensure barrier protection from the given working conditions.

After thorough chilled iron grit blasting metal reclamation is carried out over heavy pitting and cavities of guide vanes using ProCoat repair, rebuilding and reclamation product to exhibit superior engineering properties and high cross linking. Over reclaimed surface ProCoat advanced high performance polymer coating filled with Ceramic is applied to protect from high volume and high velocity water flow from spiral casing of hydro turbine.

Thick sludge storage along with agitation causing corrosion and abrasion. After draining entire tank surface blasted with chilled iron grit for required surface profile. ProCoat advanced corrosion and abrasion resistant coating was applied with all necessary quality checks. This sludge tank is performing since 3 years without any repair or maintenance to coating.

External surface gets corroded due to continuous exposure to surrounding humid conditions. To offer desired protection to resist corrosion, ProCoat team carried out application of coating system following standard quality application methods.

High volumes of gases and air with suspended solids get scrubbed / washed with water spray inside the ventilation sump causing high degree of corrosion and erosion of mild steel surface leading to punctures. Over newly fabricated ventilation sump tank, ProCoat Coating System was adopted to protect this ventilation sump tank internal and external surface. Internal surface was thoroughly cleaned by means of chilled iron grit and external using copper slag. Proper surface profile was achieved, contaminations were completely removed. ProCoat high performance advanced polymer coating applied maintaining proper coating thickness. Integrity checks done using holiday spark tester to ensure proper coating to obtain longer maintenance free life of the ventilation sump tank.

Ventilation Sump Tank Internal & External

ESP Tank Cavitation and pitting corrosion is found in this ESP tank internal surface due to flowing crude gases containing dust, moisture and corrosive substances which reacts with mild steel leading to adverse affect on surface. After carrying out thorough blast cleaning and obtaining SA2.5 finish with 100+ microns surface profile along with contamination free surface, ProCoat advanced, 100% solids, high functionality, chemical and corrosion resistant coating system was applied to effectively resist abrasion and corrosion on ESP tank.

ProCoat advanced high performance polymer coating applied to these two silencer tanks and four bends to protect against severe corrosion and abrasion due to gushing high pressure gases along with abrasive dust particles.

ProCoat polymer coating applied to hot water tank in a five star hotel to protect against corrosion.

ProCoat polymer coating protects external surface of Silo from saline corrosion due to saline environment and temperature fluctuations.

ProCoat polymer coating protects these I - beams & mild steel frames from severe corrosion due to continuous exposure to high temperature steam generated due to quenching of molten steel.

ProCoat polymer coating protects LRS tanks internal and external against severe attack of corrosion.

ProCoat high performance advanced polymer coating applied after thorough surface preparation to protect against severe corrosion, abrasion and temperature 250oC.

ProCoat high performance advanced polymer coating applied after grit blasting and contamination removal to protect against severe attack of corrosion.

ProCoat polymer coating is applied to this tank after thorough surface preparation to protect against concrete corrosion and seepage.

ProCoat high performance polymer coating is applied internally to protect against abrasion and externally to protect against corrosion.

ProCoat polymer for rebuilding is used to rebuild worn out shafts. It is machinable, exhibits excellent compressive strength and resistance to temperature on curing.

Pipelines External

ProCoat high performance polymer coating protects pipeline external against corrosion, abrasion and corrosive material. Below pipelines are in various different environment from mild to severe conditions and handling different media like chemicals, water, gas etc. ProCoat products have withstood all conditions.

Conventional painting / coal tar found ineffective in metal protection due to continuous condensation, exposure to corrosive atmospheric pollutants. Inspection on various penstocks revealed extreme pitting and cavities on surface. ProCoat advanced coating systems are designed for providing “barrier protection” to such penstocks without allowing moisture ingress and enhancing life for extended periods without any sign of rusting.

Extreme pitting, cavitation corrosion as well as abrasion due to high volumes of water and silt being carried through these penstocks is the cause of problem. In-spite of having conventional coal tar epoxies, these severe problems were noticed in many penstocks. A high end, tough, barrier protection along with engineered strengths like abrasion, impact, high impermeable coating from ProCoat will enhance the life span of these critical equipment.

Penstock External & Internal

Hot Water Header

External surface of these hot water headers are under continuous exposure to hot steam, which is resulting in severe corrosion. Surface of these headers were blast cleaned using copper slag abrasive medium and application of ProCoat advanced polymer coating was carried out. Necessary quality checks were done to ensure long term protection against corrosion.

All these pipes are continuously exposed to moisture and fumes leading to severe corrosion and also punctures. Due to the criticality of work space, these multiple pipes were brush blast cleaned along with water jet cleaning to ensure desired surface profile. ProCoat coating system was applied to safeguard the main & multiple connecting pipes from getting punctured due to pitting corrosion.

Main Furnace Feeding Pipes

ProCoat polymer coating protects internal surface of these gas pipelines against chemical corrosion and abrasion. ProCoat system extended life by 5 plus years of these ducts.

ProCoat high performance polymer coating protects pipelines and reducers against high abrasion and corrosion. These reducers and pipes handle high abrasive slag and slurry. Considerable life enhancement is established with ProCoat system.

ProCoat advanced polymer coating applied over submerged filter bed supporting channels and beams to protect them from abrasion, corrosion and hot water immersion effect as these working conditions causes high degree corrosion and erosion of structures.

Thickener In below photographs you can see few different types and design of thickeners protected by ProCoat. Cause of abrasion and corrosion are quite similar to each type. Rotating mechanism of thickeners are getting corroded & abraded during operation. As thickener mechanism is submerged and in contact with medium which cause corrosion & particles inside the medium cause abrasion. All parts of rotating mechanism are thoroughly blast cleaned ensuring contamination free surface & obtaining desired surface profile. ProCoat applied advanced chemical & abrasion resistance coating system with quality checks for coating integrity. Some of these thickeners have already crossed more than 5 years without problem.

Thickener continued... Since the medium may have many constituents which could cause severe corrosion, abrasion and surface contamination the surface preparation procedure has to be very strictly adhered too. ProCoat abrasion and corrosion resistant coating was applied with utmost care at edges, weld joints, flanges and crevices.

Asia’s Biggest Iron Ore Thickener

ProCoat takes pride in protecting Asia’s biggest iron ore thickener. ProCoat advanced high performance polymer coating wass applied to this huge thickener to protect entire mechanism like rack arms, feed wall tank, centre shaft, cones etc. from severe corrosion and abrasion due to continuous immersion and presence of high solids in slurry. Coating applied after thorough contamination removal, copper slag blasting and with all relevant quality checks to ensure barrier protection from the given working conditions. Surface profile of SA 2.5 (75 microns) achieved. Salt checks, detergent washing, wet film thickness, dry film thickness and holiday spark testing wer done to ensure quality.

Sludge Clarifier Abrasion and chemical corrosion is observed on metal surface of these rack arms which are under immersion of hot and corrosive liquid drained from scrubbers. This application was handled as explained earlier in thickener as the effects of abrasion and corrosion are same on both.

These structures & platforms are corroded due to hot steam coming from adjacent filter beds. Blast cleaned & coating with ProCoat coating system to retain the dimensional strength which otherwise was at alarming stage.

CDI Platforms & Structure

Ship-Unloader Saline Corrosion Ship-unloader equipment having total surface area of 3000 square meters is suffering from severe corrosion due to continuous exposure of saline breeze and deposition of saline salts in presence of moisture over its metal surface causing accelerated corrosion. Conventional synthetic / epoxy paints are not able to offer metal protection. It is found that in-spite of having paint over its surface severe metal loss took place leading to replacement and welding of certain parts on this ship-unloader.

ProCoat Specialities service team followed and implemented international standards in safety system, surface contamination checks, copper slag blast cleaning, surface finish, profile checks, application of ProCoat advanced polymer corrosion protection coating, coating thickness checks, coating integrity checks and finally house keeping work. Copper slag blasting carried out to remove existing multiple layers of deteriorated paint and to reveal “near white metal finish” as per Swedish SA2.5 standard. Obtained surface is matched with ISO shade cards. Over blast cleaned surface contamination checks carried out to find the adsorbed salts by silver nitrate test method and on ensuring contamination freeness, second round of blasting done, surface profile / roughness measured with Elcometer Profile Gauge and on achieving average 75 microns, proceeded for application of ProCoat advanced saline corrosion protection coating system.

Ship-Unloader Saline Corrosion continued...

Ship-Unloader Saline Corrosion continued...

Uncompromised quality workmanship along with strict adherence to safety

during work execution

Working in tandem with

operations of ship unloader, which is possible due to proper

planning & scheduling tasks as per situations

On each and every part of ship unloader including intricate areas, ProCoat coating system was applied with tynex bristle brush and nylon roller directly over blast cleaned, contamination free and rough surface to ensure optimum adhesion. Chemical bonding, mechanical interlocking of applied coating takes place with the substrate to form a corrosion resistant lining over ship unloader surface. Frequent wet film thickness checks carried out. Being 100% solids in nature both wet and dry film thickness of applied ProCoat coating will remain same without any shrinkage of applied film. To match colour coding requirements a UV and weather resistant polyurethane coat was applied over and above ProCoat system. This stringent execution method and corrosion resistant barrier properties of ProCoat coating over other ship loaders and jetty structures have shown, standing protection performance even after completion of 7+ years without any sign of corrosion in saline environment.

Ship-Unloader Saline Corrosion continued...

Overhead conveyor supporting structures in Jetty area are protected by ProCoat coating system after very thorough surface preparation by means of copper slag blasting, contamination removal along with thorough quality checks. Protecting since 7 plus years now.

Proven Performance Of ProCoat Coating Systems For Saline Corrosion at Jetty Area

Proven Performance Of ProCoat Coating Systems For Saline Corrosion at Jetty Area continued...

ProCoat high performance advanced polymer coating systems offered to Electricity Boards along with application services to protect their huge transmission towers located in aggressive chemical, saline, industrially polluted environments where conventional paint systems like aluminium, epoxy, zinc rich paints fail in very short periods. In these environments ProCoat systems are absolutely protecting transmission towers without any sign of rusting since almost 5 years with a life expectancy of 10 plus years.

ProCoat provides solution for external protection of marshalling boxes in switchyard of electricity department from saline and industrial exposure.

ProCoat advanced polymer coating protects pumps external and internal surface against corrosion and abrasion from the effect of corrosive & abrasive slurry.

ProCoat advanced polymer coating protects MS moving conveyor of Slag Granulation Plant 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 in punctures.

ProCoat polymer coating is applied to protect these screens from severe attack of corrosion and abrasion caused due to handling abrasive iron ore slurry.

Surface of steam fan casing was thoroughly blast cleaned using abrasive media to obtain SA 3 (Swedish standard), with a profile of 100+ microns surface roughness. Over this prepared surface, ProCoat advanced polymer coating was applied using quality application procedure to form an impermeable, tough, chemical, abrasion and temperature resistant lining over the surface, which prevents chemical attack even under severe conditions. Applied coating also isolates steam fan casing internal surface from physical and electrical contact of chemical medium to protect from chemical corrosion. Fully cured coating exhibits a low friction, glossy surface which reduces the “friction to flowing medium” which in turn reduces “contact time” of medium and increases out flow. An equipment with right protection adds to increment in efficiency of productivity, which most of the times goes unnoticed.

Steam Fan Casing Internal

Chimney Chimney was to be replaced in view of reduction in metal thickness due to continuous reaction with acidic hot and wet steam as well as suspended abrasive particles during quenching operation of red hot slag. Internal surface of this stack was blast cleaned to SA2.5 with an average surface profile of 150 microns. Over this prepared surface ProCoat coating applied initially with heavy hand pressure to ensure complete wetting of profiled surface followed by subsequent coats to attain the recommended thickness. During and after cure, thickness measurement checks were done. Integrity check was carried out with DC Holiday Spark tester.

Top Gas Packing Scrubber Large volumes of chemically contaminated wet dust gets settled over the surface of this packing gas scrubber making it an excellent conductive electrolyte inducing chemical corrosion. Heavy pitting and cavitation in form of metal loss was observed specifically at nozzle areas due to high impingement and abrasion caused by directional flow of the medium. Two rounds of blast cleaning was carried out each with copper slag & chilled iron grit in order to attain surface free from contamination with intermediate detergent and fresh water cleaning. Swedish SA3 standard of white metal finish was achieved with average 125 microns surface roughness. Over pitting and cavities ProCoat’s metal rebuilding product was used followed by abrasion & chemical resistant coating. Coating film integrity checks were carried out.

After thorough chilled iron grit blasting metal reclamation is carried out over heavy pitting and cavities of scrubber using ProCoat repair, rebuilding and reclamation product with high cross linking. Over reclaimed surface ProCoat advanced high performance polymer coating filled with Ceramic and Kevlar is applied to protect from high temperature gaseous slurry and water impingement. This coating has exceptionally high chemical resistance, abrasion resistance and can tolerate high temperatures. ProCoat system effectively extended life of this scrubber by 5 plus years without any deterioration.

Initially thorough chilled iron grit blasting is carried out followed by filling pitting and cavities of scrubber using ProCoat repair, rebuilding and reclamation product exhibiting superior engineering properties. Next, ProCoat high functionality coating is applied to protect from high temperature gaseous slurry and water impingement. ProCoat system effectively extended life of this scrubber by 5 plus years without any deterioration.

Cooling Gas Venturi & Mist Eliminator Vessel Venturi scrubber surface was undergoing extreme chemical corrosion leading to heavy metal loss in form of cavities finally causing punctures in the shell. Corrosive gases being scrubbed with water jets forming chemical sludge deposition over surface which accelerates process of chemical reaction with metal surface. External cladding carried out in many places for strengthening. Internal surface taken up for metal reclamation and chemical protection with ProCoat engineered polymer systems. Surface preparation prior to coating application was done by consecutive blast cleaning methods, initially by copper slag & later with chilled iron grit in order to obtain the Swedish SA3 standard of white metal finish with an average 125 microns surface (profile) roughness. Pits and cavities were initially reclaimed with ProCoat metal rebuilding system which cures to a tough high strength metal deposition, which in turn prevents further propagation of cavities. On entire vessels surface ProCoat advanced coating system application carried out to provide a barrier coating which is chemical and temperature resistant.

Top Gas Mist Eliminator Large cavities & pitting were found on the internal surface of this top gas scrubber equipment due to impingement of abrasive medium flowing inside the scrubber. Gases with suspended particles at high speeds aided to metallic deterioration & scorings over the surface. Blast cleaned initially by copper slag & later with chilled iron grit in order to obtain Swedish SA3 standard white metal finish with an average 125 microns surface (profile) roughness. Pits and cavities were initially reclaimed with ProCoat metal rebuilding system which cures to a tough high strength metal deposition, which in turn prevents further propagation of cavities. On entire vessel’s surface ProCoat advanced coating system application carried out to provide a barrier coating which is chemical and temperature resistant.

ProCoat polymer coating protects bag house doors against extreme corrosion due to sulphuric acid and temperature.

ProCoat polymer reinforced with ceramic carbide is used for rebuilding faced areas of Sepax fan. It protects against impingement and abrasion due to fine dust.

Circulating Water Pump Thermal Power plant’s submersible circulating water pumps are subjected to abrasion & corrosion due to immersion. Internal surface undergoes “cavitation-erosion”, “abrasive erosion” & “corrosion”. ProCoat coating systems were recommended for enhancing the life for extended periods.

ProCoat Advanced Polymer Coating Systems effectively address above said problems in pump and enhances life of the pump. Advanced chemistry of coating systems ensures tough, high mechanical strength, excellent adhesion with the substrate resulting in longer life. Smooth finish of coating reduces friction of fluid flow thereby increasing outflow. Reduction of contact time of fluid reduces formation of cavities. As the coating offers barrier type protection to metal and due to absolute isolation of fluid contact with metal electro-chemical reaction is prevented and pump protected from corrosion. ProCoat coating systems are designed with exceptional engineered parameters like, 100% solids, no solvents, no shrinkage of applied film, no cohesive stress in applied film. Forms an highly impermeable three dimensional high density complex polymer matrix structure

which prevents ingress of water molecules through it. Offers barrier protection to applied part without undercutting or underneath corrosion.

Even in the event of mechanical damage, problem will be limited to localized damage and will not propagate beneath the applied film. Hence rest of the coated surface will be under protection.

Deterioration of pumps is basically because of Cavitation Erosion, Abrasive Erosion and Corrosion.

Circulating Water Pump continued...

Tube sheet & tube interface is subjected to bimetallic corrosion due to dissimilar metallurgy in presence of conductive electrolytic medium (either raw water, seawater etc). Circumferential area of sheet at this interface exhibiting deterioration in form of cavities leading to leakage.

Condenser Tube Sheet - Bimetallic Corrosion

The above faced problem leads to malfunctioning of condenser’s intended purpose. In order to avoid this high end polymer lining has to be applied over the entire tube sheet surface without any flaws so that the lining acts as a barrier isolation between tube-sheet and medium. ProCoat coatings used for this application are engineered to offer best protection to condenser tube-sheet by forming a highly complex, high density, three dimensional cross-linking polymer matrix with high impermeability and cures to a tough yet flexible lining to take up contraction and expansions. High dielectric strength to prevent electron flow, excellent immersion resistance, chemical resistance, wet temperature resistance along with cold wall resistance properties of coating aid to protection.. Application method adopted by ProCoat team ensures optimum adhesion of coating with the substrate so that coating sustains over condenser tube sheet for extended period and protects from bimetallic corrosion. Standard procedure of application methods were adhered to in executing the work of this condenser handling sea water.

Power Plant Condenser Water Box

Along with condenser tube sheet, water box is one more area where long term protection is required. Conventional methods like rubber lining, epoxy painting or coal tar painting adopted by power plants and refineries etc are not meeting industry requirements. There is a loss of metal thickness in form of cavitation and pitting that occur during the operation, which is evident from the pictures. ProCoat Specialities with hands on experience has provided solutions with it’s advanced polymer coating system designed with high end engineered properties to effectively prevent physical and electrical contact of cooling medium with water box surface. The high end quality ensured during surface cleaning, coating application and quality checks makes the coating dependable, durable and desirable.

ProCoat high performance polymer protects against corrosion and abrasion. Also, reduces friction.

After thorough surface preparation ProCoat high performance advanced coating is applied to protect against corrosion from hydrochloric acid. Coating is amine cured with high resistance to chemicals and acids.

After thorough surface preparation ProCoat advanced polymer coating is applied to protect against corrosion from aggressive chemicals and fumes from process.

After thorough surface preparation ProCoat polymer coating is applied to protect against corrosion from aggressive chemicals and fumes from process.

Pump Base Frames

Pump base frames were blast cleaned and coated with ProCoat coating system to protect from corrosion of metal leading to improper balance and vibration of pumps during long run. Application over these frames done with ProCoat coating offering barrier protection to metal even under continuous immersion conditions. These frames serve the purpose of support to the pumps being mounted and once they get corroded vibrations are noticed effecting pump efficiency and increase in maintenance.

ProCoat high performance polymer coating is applied after grit blasting and contamination removal to protect against corrosion due to chemical attack.

ProCoat polymer coating is applied after grit blasting and contamination removal to protect against corrosion due to continuous contact of acidic and alkaline waste liquids, mud and moderate temperature.

ProCoat advanced polymer coating is applied to pump impeller to ensure protection against pitting, corrosion and abrasion.

ProCoat polymer with Kevlar reinforcement is used for reclaiming damaged portions, edges and cavities of impeller handling abrasive slurry. It provides mechanical strength and protects against corrosion & abrasion.

ProCoat products are best choice for arresting online oil leakages without draining oil from CT, PT, transformers, MOCB, OLTC top covers, bushings, radiators, conservator tanks, welding cracks, pin holes etc in power transmission & generation industries.

ProCoat proven products applied over mild steel & galvanized iron structures in substations to protect them from aggressive corrosion caused by exposure to saline 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. ProCoat coatings are extending life by more than 5 years.

ProCoat products helps in arresting SF6 gas leakage from circuit breaker. Leakage is detected from cemented portion i.e., joining area of metal and ceramic. Step by step method used for leak arresting and after that reinforcement.

ProCoat coating system is applied over exposed portion of radiator fins, more specifically edges, which are prone to rapid corrosion due to welding, bending and jointing of mild steel. This protects radiator edges from corrosion and oil leakages.

ProCoat coating system has excellent dielectric strength which prevent electric shocks to people operating control panels. Coating works as insulation. Also, grip system 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 an excellent barrier and prevents ingress, thereby extending life of concrete surface.

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