Belzona 5811 Protects Electrical Control Panel in Brewery Unit

admin — Tue, 27 Feb 2024 07:25:45 +0000

A prominent brewery unit in India was facing corrosion damage to its electrical control panel due to exposure to fumes. The corrosive environment had caused deterioration, risking the functionality and safety of the control panel.

Belzona Solution:

To address the corrosion issue, our Belzona Team recommended the use of Belzona 5811.

Belzona 5811 – Is a 2-part epoxy coating which provides outstanding chemical resistance and protects equipment operating under immersion in aqueous solutions up to 50°C (122°F) from the effects of corrosion. This solvent-free material can be easily applied by brush or spray to virtually any metallic and non-metallic surface, simplifying maintenance works.

Surface Preparation Procedure:

Cleaning: The surface of the control panel was thoroughly cleaned to remove any dirt, grease, or other contaminants using a suitable cleaner.

Abrasive Blasting: Abrasive blasting was performed to achieve a surface cleanliness of at least Sa 2.5 (ISO 8501-1). The surface profile was measured to ensure it met the required roughness for optimal coating adhesion.

Masking The Switches and Other Control Devices: Any areas not to be coated were carefully masked off to prevent overcoat. (See the picture above)

The Application: Two coats of Belzona 5811 was applied to the prepared surface using a soft bristled brush and roller, ensuring a uniform and adequate thickness. First coat was left for 2 hours before the second coat was applied.

Curing Time: The coating was allowed to cure at room temperature for the specified time to achieve full strength and chemical resistance. The curing time for Belzona 5811 depends on the ambient temperature and thickness of the coating. It took 24 hours to achieve full cure at room temperature.

Reinspection Result:

The control panel was re-inspected after a year and found to be in perfect working condition without showing any signs of corrosion or coating degradation.

Corrosion Repair and Protection in a Chemical Plant

admin — Thu, 01 Feb 2024 06:35:24 +0000

In this case study, we explore the successful application of Belzona products for the repair and protection of a rubber-lined top cover in a chemical plant producing demineralized (DM) water. The vessel handled liquid hydrochloric acid (HCL) with a concentration of approximately 33%, operating at a temperature of 40°C.

The chemical plant encountered external corrosion on the top cover of a vessel, which prompted the need for immediate intervention to prevent further deterioration and ensure the integrity of the equipment.

Problem Identification: The top cover, constructed with rubber lining, exhibited signs of corrosion, potentially compromising the structural integrity of the vessel. To address this issue, a comprehensive repair and protection plan was devised by Nicco.

Surface Preparation: The initial step involved thorough cleaning of the surface, where rust and remnants of previous paint were meticulously removed using hand tools. This process ensured a smooth and contaminant-free substrate for the subsequent application of Belzona products.

Belzona Products Applied:

At first Belzona 4301 (Magma CR1) was applied to cover the pitted and uneven surfaces: Belzona 4301 is a high-performance ceramic-filled epoxy coating designed to provide outstanding erosion and corrosion resistance. This product is specifically formulated for the protection of equipment exposed to acidic environments.

Then Belzona 1212 was used to cover the first layer of Belzona 4301: Belzona 1212 is a surface-tolerant, multi-purpose epoxy coating designed for the repair and protection of metal and rubber substrates. It offers excellent adhesion to various surfaces, including rubber.

Belzona 4311 (Magma CR3) was used as a Top coat for additional protection against chemical attack: Belzona 4311 An elastomeric, abrasion-resistant lining designed to protect against chemical attack and abrasive wear. It is suitable for applications where flexibility is essential, making it ideal for rubber-lined components.

This application technique aimed to create a protective barrier against the corrosive effects of the 33% HCL solution.

Safety Mitigation: The repair work was conducted in a safe environment, adhering to all safety standards. The chemical plant prioritized the well-being of personnel and ensured compliance with safety protocols throughout the project.

Curing Time: Following the application of Belzona products, the system was allowed sufficient time for curing, ensuring the products achieved their optimal mechanical and chemical properties.

Re-inspection and Results: A year after the repair, a thorough re-inspection was conducted, revealing the vessel’s top cover to be in perfect running condition. The Belzona solution effectively protected the rubber-lined surface from corrosion, validating the success of the repair and protection measures.

corrossion protection – NICCO ENGINEERING SERVICES LIMITED

Belzona 5811 Protects Electrical Control Panel in Brewery Unit

Corrosion Repair and Protection in a Chemical Plant