Corrosion of pressure vessels is a critical challenge for industrial plants, requiring quick, safe and cost-effective solutions to restore structural integrity and ensure operational safety.
In the case of a petrochemical plant in the Persian Gulf, a corroded pressure vessel was threatening the stability of the plant with obvious signs of cavitation and risk of imminent leakage. Complete equipment replacement was neither practical nor cost-effective, while traditional welding options posed safety risks and environmental problems, especially considering the extreme temperatures in the region.
In this case study we can see Devcon® solutions for pressure vessel corrosion and repair.
The problem of implantation
A petrochemical plant located in the Persian Gulf region had a corroded pressure vessel that needed urgent repair. With obvious signs of cavitation within the equipment and an increasing risk of leakage, the customer was looking for a safe, quick and cost-effective repair solution.
Replacing the entire equipment was neither quick nor cost-effective. Welding was not appropriate due to safety issues and environmental factors. In addition, temperatures in the region could reach 122°F / 50°C. Since most repair work had to be done manually inside the 108-inch (9-foot) carbon steel vessel to protect the equipment from corrosion and leakage, repair work had to be quick and easy.
The solution with Devcon® products.
High-performance Devcon® Titanium Putty and Devcon Brushable Ceramic coatings were chosen to quickly repair and return the pressure vessel to service. Here are the steps:
To prepare the surface of the inner tank shell, the lower half of the tank was blasted SA3 – SSPC5 with a surface profile of 80μ to 90μ. The surface profile control test was performed by the customer to ensure that the required specifications were met.
Part A and Part B of Devcon titanium putty were thoroughly mixed on the mixing table using a 3″ spatula. This mixture was used to fill and correct the anomalies/defects in the vessel.
Devcon Titanium putty was then spread to fill all the anomalies, then the thickness of the application was unified on all the corrosion points. After curing, the first layer of Devcon Brushable Ceramic was applied with a hand brush.
The wet film thickness of Devcon Brushable Ceramic was confirmed to be within the acceptable range (350 to 500 microns). An additional layer was applied using the same methodology. When finished, the Holiday detector did not detect any spark.
Results obtained from the repair of the pressure vessel
Highly durable coatings
Devcon® Titanium Putty and Devcon® Brushable Ceramic Blue coatings provide long-term corrosion protection that restored the pressure vessel to its original and intended operating condition.
Safe installation
The cold welding offered by the Devcon repair system makes coatings a much safer alternative to welding in a petrochemical plant; the main idea behind the creation of Devcon in 1947: to avoid hot work (welding) when dealing with explosive environments.
Quick and easy application
Areas with pitting, corrosion, and erosion were filled and repaired within hours, as Devcon coatings are quick to mix and easy to apply.
In addition to the advantage of having an easy and safe application, Devcon Coatings have helped extend the life of the pressure vessel by avoiding pressure, avoiding the need for equipment replacement, and thus reducing maintenance costs and downtime. Reduce overall maintenance costs and downtime.
